flexographic

Flexographic printing, or flexography, is a relief printing process that uses flexible plates to transfer ink to a substrate. The image areas on the plate are raised, and prints are produced by transferring ink from a metered ink source to the plate, then to a rubber or composite blanket, and finally onto the substrate as it passes through printing cylinders. The plates are typically made from photopolymer or elastomer materials and are mounted on a plate cylinder. Anilox rollers meter a controlled amount of ink onto the plate, with doctor blades shaping the ink before it transfers to the plate.

This method is characterized by its ability to print on a wide range of substrates, including paper, film, and especially porous or non-flat materials. It is widely used in packaging and labeling, where high-speed, continuous web printing is advantageous. Common applications include corrugated cardboard, flexible packaging films, shrink sleeves, and various consumer product labels. The process supports large-format runs and is adaptable to complex color schemes with rapid changeovers.

Inks used in flexography include water-based, solvent-based, and UV-curable formulations. These inks, combined with photopolymer or rubber plates, enable printing on diverse surfaces while offering relatively fast production times and lower plate costs for long runs. Modern flexography emphasizes image quality improvements, color control, and process automation, including better ink management, plate technology, and advanced register and color matching systems.

Advantages include high speed, versatility across substrates, and cost effectiveness for long runs. Limitations involve achieving lithographic-level resolution and fine detail, color reproduction complexity, and plate wear. Ongoing advances continue to enhance sharpness, consistency, and environmental performance.