Flexography

Flexography is a form of relief printing that uses flexible plates with raised image areas to transfer ink to a substrate via a rotating blanket cylinder. The ink is metered by an anilox roller and transferred from the plate to a rubber or synthetic blanket, then onto the substrate. Modern presses enable high-speed web production and can print on a wide range of materials using various ink chemistries, including water-based, solvent-based, and UV-curable inks.

Key components of a flexographic system include the plate cylinder, blanket cylinder, impression cylinder, ink metering system (often anilox), doctor blade or chamber, and drying or curing units. Plates are typically made from photopolymer or polymer-coated materials and may be mounted on cylinders in desktop, semi-automatic, or fully automatic configurations. Inline press configurations often integrate post-print processes such as lamination, varnishing, or coating.

Substrates printed by flexography span paper, paperboard, plastics, self-adhesive labels, films, and corrugated board. The method is particularly prevalent in packaging and labeling, but has applications in newspaper printing and decorative graphics. The process is valued for its ability to print on uneven or porous surfaces, its suitability for long production runs, and relatively low per-color cost.

Advantages include high production speeds, broad substrate compatibility, and versatility with different inks. Limitations involve lower image resolution compared with lithography, potential color-to-color registration challenges, and the need for careful ink management and plate wear considerations. Flexography remains a dominant technology in packaging, labels, and applied graphics worldwide.