Hot Foil Stamping Summary

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This is the summary of a dry printing technique the complete file u can ask me for it. Created by Eng.Shady Ahmed Atef
  Hot Stamping is dry printing method (No any degree in chemistry) in which a heated die and foil are usedto apply graphics to a part.Hot stamping is a process in which an engraved image, hot stamping die or type, is heated then forceddown against a part with a marking foil sandwiched in between.Using foil printing is a very effective way to add security to your document. It cannot be duplicated byscanners or copiers. Main Components of the Hot Stamping Process: ANVIL usually made of a hard rubber or phenolicFOIL ROLL LEAF is the ink of a hot stamping operation. It is made up of a carrier with a series of coatings to be transferred.SUBSTRATE a wide variety of substrates is suitable for the hot stamping process. Surface tension of thesubstrate has the same affect on hot stamping as it does on printingHOT STAMPING DIE the hot stamp die is an engraved plate where the non-printing areas are relieved.HEAT + PRESURE + TIME = FOIL TRANSFER Foil is transferred to the substrate when a heated dieforces the foil onto the substrate against the anvil.  A)Small and Medium sized production and substrates: - Principles are:1.Flat Foil Stamping2.Sculpted Foil Stamping (Multi-Level Foil Stamping)3.Vertical Foil Stamping a maximum of 90 degrees4.Peripheral Foil Stamping entire 360 degrees- Machines are:1.Hand-operated Foil Stamping Machine2.Pneumatic Foil Stamping Machine3.Foil Fuser Machines  B)Large sized production - Principles are:1.Flat-Flat Principle2.Round-On-Flat Principle3.Round-On-Round Principle- Machines are:Categorized to web and sheet fed stamping or embossing machineROTARY HOT STAMPING Short dwell time is also the reason rotary hot stamping is able to produce agreater level of detail than the best flat bed equipment.ROTARY HOT STAMP EQUIPMENT First it must maintain the desired temperature of the die. Secondit must hold the die securely in position to produce even depth of impression through heavy and lightcoverage regions of the die.TEMPERATURE CONTROLIMPRESSION CONTROL The second task of any rotary hot stamping system is that it maintains aneven depth of impression.  Die materials are divided in to metal and silicon rubber dies in which four metal materials are mostoften used for die construction: magnesium, copper, steel and brass. The material used for a specificapplication depends upon a number of factorsTooling is CNC engravingSilicon   they will conform much better to parts that are not perfectly flat Types of Dies 1.Single-Level straight and level2.Multilevel distinct levels of depth are used to add a variance in dimension to the image3.Round Edge provides a soft edge effect rather than a hard ruled edge.4.Beveled Edge provides the appearance of combining the softness of a round edge with the welldefined lines of a distinct edge5.Sculptured a hand-tooled die6.Rotary Die Cylinders ã Copper alloys used exclusively in rotary stamping in which the time taken in one stroke which iscalled dwell time is extremely and very short. ã Thermally compensated for precise register and fit. ã Available for all narrow to mid web presses. ã Superior surface finish for improved accuracy. Foil is an extremely thin polyester film material containing a dry pigment that is transferred to substrate(such as: paper) by the use of heat and pressure. Foil Composition: Film Carrier: The thinner the carriers while all other things being equal, the faster the foil will transfer Release Coat: Allows the other layers to release from the film carrier upon application of heat &/or  pressure in which this layer affects whether or not a foil is suitable for fine copy or heavy coverageLacquer, Tie or Color Coat provides a hard abrasion resistant surface to the foil when applied and carriesthe color tint in the form of pigments or dyes which is required to make gold or other colored metallic because the metallic layer is always made from aluminum.Metal Coat: Generally composed of aluminum to provide the reflective qualities and opacity desired inmetallic foils.Adhesive or Sizing Coat: The final layer in the foil construction is the sizing which serves to bond the foilto the substrate being stamped. Types of Hot Stamping Materials: Metallic Foil Construction: has a metal like sheen   and gives a shiny and shimmering look to the foilstamped design. Such foil paper is available in different metal shades such as gold, silver, bronze, andcopper just to name a few.Pigment Foil Construction:Gloss Pigment Foil Paper not have a metallic look but has a very high glossy finish.Matte Pigment Foil Paper a dull finish as opposed to a glossy finish  Holographic Foil Paper: hologram is a 3-dimensional image that can provide a distinctive appearance tospecific areas of a digitally printed application.Many other applications can be applied on the hot stamping machines without stamping or with theaddition of stamping to it like: ã Debossing opposite of embossing it is indented ã Embossing by providing a three dimensional or raised effect on selected areas ã Blind Emboss provides a clean and distinctive or subtle image on paper stock does not include the useof ink or foil to highlight the embossed area. ã Registered Emboss a process that places the embossed image in alignment with another elementcreated with ink, foil, punching, or with a second embossed image. ã Combination Emboss embossing is the process of embossing and foil stamping the same image. Itinvolves imprinting and aligning foil over an embossed image to create a foil emboss. ã Pastelling the process of using a combination die to provide a subtle antique appearance to a substratethat is embossed and foil stamped. ã Glazing an embossed area that has a shiny or polished appearance. ã Scorching similar to glazing except that it is not used to polish the stock. Instead, scorching does whatit implies: as the temperature of the die heating plate is increased beyond a normal temperature range,a scorched effect is created in the embossed image, which results in an antique or shaded appearance. Results: 1-Hot stamping process is a dry method of printing that no any types of chemistry.2-The idea of hot stamping was not invented but was practiced from the ancient Egyptians.3-Main Components of the hot stamping are: 1- Anvil, 2- Substrate, 3- Foil roll relief and 4- Die.4-For foil transfer three main conditions must be achieved and they are: Heat, Pressure and Time.5-Hot stamping machines can stamp any substrate except metals or non - porous materials.6-Most of the machines of hot stamping were hand operated and still operated in this way and inaddition to that the basic principle are based on the hand operated stamping machines.7-Hot stamping machines were modified and developed in the European countries to supply theenlarging market of hot stamped products in all fields from printing paper products to polymersand others.8-The development in the machines were in copying almost the mechanism of sheet fed and web fed printing machines to increase the speed and productivity.9-Cylinders or die cylinders been used in the modern machines and it acts like gravure or flexo printing cylinders.10-Foil represents the ink in the offset printing.11-Foil is treated in the modern machines like a reel considering many factors like tension and the foilleads in the machine.12-Hologram foils is used in most of the stamping productions as security logos and for decorationssome times.13-Any hot stamping technician must consider the type of substrate will be stamped and the design of the foil and the die that will take the heat and pressure. Hot Stamping Advantages: 1.The process and set-up is very easy2.There are no chemicals or paints.  3.No unnecessary steps of mixing paints and solvents or cleaning up.4.Both thermoplastics and thermo sets can be hot stamped along with: leather, fabrics, paper  products, coated woods, and prepainted metals.5.All types of shapes can be hot stamped as well.6.After the hot stamping is complete, the parts are immediately ready for handling and packaging. Hot Stamping Disadvantages: 1-In manual stamping, the machines have cycle start buttons, which must be pressed and heldsimultaneously, to help avoid hands and fingers from being placed in harmful places on themachine. This is also the reason for there to be only one person operating a machine at a time.2-One more hazard is the hot die. No matter if the die is made of silicone or metal, it does get veryhot. Below the cycle start buttons are highlighted. Hologram Foil Advantages: 1-General design hologram hot stamping is available in silver, gold, green, blue, etc. as well as thecustom design hologram hot stamping foil.2-Selection of hologram hot stamping transfer products for use is on a wide range of substrates andapplication equipment.3-It has a strong visual appeal and is easy to verify4-It is a superior security device as it is virtually impossible to remove it from substrate and it isdifficult to replicate. You can use it to authenticate credit cards or other items including securitydocuments.5-It is easy to incorporate or apply to product and packaging and they can be stamped on to the package or on to a pre-printed label, there by authenticating the carton or label and therebyassociating it with product itself.6-Hologram Hot Stamping is relatively cost effective to produce and use.
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