Image 1: Producing stunning graphics and lettering that really pops is made easy with a direct-to-substrate printer and computerized rotary engraver.

Whether it’s an issue of capability or capacity, turning down a potential customer is something no awards and engraving professional likes to do. Yet many are faced with this reality because they simply lack the technology or turnaround time required to meet the customer’s requests. While outsourcing has long been a workaround for this type of issue, it also has its drawbacks. Outsourcing has led to longer lead times, reduced profits due to the added expense of using a third party, and a potential loss of customers, all of which figure prominently into your profit margin, or lack thereof.

In order to fulfill services once outsourced, many awards and engraving professionals have begun to look at ways to incorporate state-of-the-art, complementary technologies. Many are finding the transition into new markets to be faster, easier and more lucrative than they had thought—especially when they can leverage their existing workflow to tackle new applications. With the right technologies, these businesses are both expanding their capabilities and opening up new avenues for generating revenue.

The Benefits Of A Capable Full-Color UV Printer

One area of the business that has typically required outsourcing has been full-color printing of engravable awards, giftware, signage and three-dimensional promotional products. Combining full-color printed and engraved applications has quickly become a popular service offering for many awards and engraving businesses. However, the technology to produce these types of personalized products has often been outside the scope of more traditional awards and engraving shops. (See Image 1)

With the advent of newer technologies such as direct-to-substrate printing, suddenly these once outsourced services can now be done in-house in a cost-effective and timely manner. This has enabled awards and engraving professionals to print photo-realistic graphics and stylized lettering onto a vast array of objects ranging from giftware, awards, prototypes and signage to promotional and industrial products. While the ability to produce full-color, engraved items is nothing new, with direct-to-substrate printing the entire workflow has changed, becoming more simplified and requiring far fewer steps than other processes. (See Image 2)

Unlike other full-color processes that utilize excessive heat, adhesive vinyl, expensive pre-treatment sprays, screens and stencils, special coated materials or even printing plates to bind the ink to the printed surface, direct-to-substrate printing eliminates the extra labor, time and costs involved in alternative methods.
 

Image 2: Creating photo-realistic graphics for full-color awards using a direct-to-substrate printer.

Image 3: UV ink and curing provides graphics that stand the test of time.

There are numerous inkjet printers that can be used to print directly onto substrates for full-color applications. However, it’s important to choose a machine that supports direct printing on objects of varying shapes and widths, and is capable of delivering durable graphics that will stand the test of time. This can be easily achieved by choosing a machine that utilizes UV curing technology, along with UV inks. These inks are formulated to be long lasting, quick drying and extremely flexible, making them ideal for use on a variety of substrates. (See Image 3)

For graphics that differentiate you from the competition, an excellent option to consider is a direct-to-substrate UV printer that is equipped with white and clear inks. White can be added as a spot color or as a flood behind CMYK to make colors stand out and pop, especially on acrylic, while clear UV ink can be used to create enhanced visual and textural effects that allow you to differentiate yourself from the competition (See Image 4). UV inks can also be used with a wide range of treated and untreated substrates, including some of the most popular materials used for producing an array of award, gift, sign and promotional products, including everything from acrylic, plastic, ADA substrates, PVC and wood to natural stone, marble and pretreated glass and metal objects. The creative possibilities are endless, and the results can be priced at a premium.

Another great advantage of using a direct-to-substrate printer for these applications is that it can be easily paired with virtually any engraving method to add stunning color and visual effects to any graphic. Getting started engraving your printed products is no more difficult than choosing the desired application, material to be used and the engraving method that will provide the best result. However, for engraving high-quality, three-dimensional graphics, a computerized desktop rotary engraver is preferred.

Rotary Engraving Adds Finishing Touches

Compatible with a broad range of substrates and materials of varying degrees of thickness, a computerized rotary engraver is the ideal complement to any direct-to-substrate printer. Unlike other methods, the rotary engraver is uniquely designed to add depth and dimension to printed graphics, lettering and logos that can’t be achieved with other engraving methods. (See Image 5)
 

Image 4: White can be added as a spot color or as a flood behind CMYK to make colors stand out and pop.

Image 5: Once printed, full-color graphics can be engraved for added depth and dimension without ruining the printed surface.

Choosing the method of engraving is fairly simple, since this is often determined by the application and the materials and tools required for carrying out the process. For signs, awards or promotional products created from acrylic or plastic, back surface or reverse engraving is preferred. This can be done using the engraving design software that came with your machine to “mirror” or transpose the text, as this will adjust the machine to engrave the back surface so the graphics and lettering can be read when the object is front facing.

Reverse engraving also allows you to create a deeper more three-dimensional look for your text and graphics, especially when the engraving is made directly to the full-color printed surface. This eliminates the need to paint fill or colorize the engraved graphics in order for them to stand out.

Another application that benefits from the combined printing and engraving is the production of full-color, durable signs. Together, these two devices make it possible to produce tamper-resistant, full-color signs with inlaid graphics that meet all ADA regulations. This process can also be used to produce color-saturated informational signs and customized directional signs for both indoor or outdoor usage by simply printing with UV ink directly onto the desired material, and then engraving the text, followed by routing out the custom shape using a rotary engraver that is equipped for this application. (See Images 6 &7)

Whether reverse engraving or simply combining prints and engraved text to add interest to a graphic, the combination of a UV direct-to-substrate printer and a rotary engraver is powerful—and transformative for your business. Together, these technologies can provide access to new markets, and help you refresh your product offerings. Remember, growing your business depends on your ability to provide new and exciting services that appeal to a broader customer base. Choosing the right technologies can take you there.
 

Image 6: Routing of full-color directional signage is made easy with a computerized rotary engraver.	Image 7: Printed, engraved and routed directional signage.

Rick Rivera is Product Manager, Engraving Solutions, for Roland DGA Corporation.

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