Block Engraving/Die Making

There are three main techniques to manufacture dies. Some dies require two or three of these techniques to achieve the optimum result.
Photo mechanical engraving uses acid to eat away the desired areas of the metal surface.
Machine engraving cuts dies with finite control over depths and angles including multiple levels.
Hand engraving is undertaken for fully sculptured dies where a detailed, 3 dimensional image is required or for combination dies.

Examples: Dies for gold blocking, embossing and debossing.

Tips:

• Dies are created through a variety of techniques and materials according to the required life of the die, the number of embossing levels, budgets and deadlines.
• Always contact your supplier for individual specifications.

Suppliers: Allkotes, Alltab Australia, Avon Graphics

Embossing/Debossing

Embossing is an adaption of the letterpress printing process in which dies are used to raise the image above the surface of the paper or board.
Debossing has the opposite effect – the image is pushed below the surface.

Examples: Covers, letterhead

Tips:

• Maintain an adequate space between small embossed elements and the edge of the paper to avoid warping in the non-embossed areas.
• Embossing over plastic or UV coated surfaces will limit the depth.
• Embossing can delaminate some plastic coatings so ensure suitable adhesives are used.
• Finer images will not achieve as greater depth as broader images.
• Always contact your supplier for individual specifications.

Suppliers: Allkotes, Alltab Australia, Avon Graphics, CP Gluing, Heidelberg Australia, Lorimier Pty Ltd, Pandoras Boxes, Prestige Bookbinders,

Process Requirements & Guidelines:

Please follow the following steps when planning for embossing:

• Minimum from grip edge to edge of emboss image – 20mm.
• Artwork requirements are the same as for printing.
• If emboss is to fit a printed image check with your supplier regarding lay and grip edges.
• Image can be supplied as a file in all common formats or as film. If supplying film then letterpress positive is required (right reading emulsion up).
• If sheets to be embossed are to be laminated, check with your supplier.
• Emboss profiles vary – most common are square relief, round relief, roof relief and sculptured. Discuss your requirements with your supplier.
• Always contact your supplier for individual specifications.

Foil Stamping/Foiling

This process, also known as gold blocking or foiling, uses the letterpress printing process, applying foil instead of ink. It is also known as foil stamping.
During the foiling process the foil is transferred to the substrate by means of a heated metal die. The shape of the die determines the shape of the stamping.

Examples: For the embellishment of all printed matter

Tips:

• Ensure the colour density of the foil is not compromised by the colour of the stock.
• To gain greatest foil clarity, avoid fine detail and small fonts.
• Never reverse out foil stamping images from the print.
• General printing inks, aqueous varnishes and wax free machine varnishes are generally OK.
• Use wax free litho inks when combining foil stamping over printing.
• Avoid foiling over UV coating because the foil may not adhere. Foiling under UV should be OK. Foiling over other coatings and varnishes are generally OK but should be checked if the image is bold.
• Excessive spray powder will cause problems with foiling.
• Always contact your supplier for individual specifications.

Suppliers: Allkotes, Alltab Australia, Avon Graphics, Heidelberg Australia, Lorimier Pty Ltd, Pandoras Boxes

Process Requirements & Guidelines:

Please follow the following steps when planning for foilstamping:

• Minimum from grip edge to edge of foil image – 20mm. More may be required if image is a large solid.
• Artwork requirements are the same as for printing.
• Do not reverse foil image area from print i.e. provide solid colour under.
• If emboss is to fit a printed image check with your supplier regarding lay and grip edges.
• Image can be supplied as a file in all common formats or as film. If supplying film then letterpress negative is required (right reading emulsion down).
• Keep spray powder to a minimum, de dust or crush run sheets if necessary
• If sheet is to be UV coated it is best to do this after foilstamping.
• Always contact your supplier to discuss other technical requirements.