Engraving Archives » PostPress

*Photo courtesy of Datron Dynamics – www.datron.com*

By Jeff Peterson, editor-in-chief, PostPress

Foil stamping and embossing engravings are the tools that drive the design and look of a final piece. The importance of engravings sometimes is forgotten – all foil stamped or embossed projects start with how the artwork is prepared for the final die. At FSEA’s Print Embellishment Conference in April 2024, a panel of engraving manufacturers shared information on the latest technologies and uses for foil stamping and embossing engravings. The panel included Daniel Rivera, H+M USA; Ross Hutchison, Universal Engraving, Inc.; and Mark Schumacher, Metal Magic.

What new technologies has your company introduced in recent years in the development and manufacturing of foil stamping and embossing engravings?

Schumacher: One of the newer additions that we have added to Metal Magic is our 3D simulations. These allow customers to have a vision of what the emboss will look like before the project begins. Once the simulation is created from the initial artwork, customers have an opportunity to see what the final emboss will look like and make modifications. Customers can increase or decrease depth or include more or less texture, and these changes can be accomplished before any type of die is produced. In the past, the customer really relied on the engraver to create the proper depth and embossing levels. Today, customers can have input on the final look before the die is made.

A newer advancement for us is to take the 3D simulation and mirror it to the print file. It is the same simulation with the print file included in perfect register. The 3D simulation technology allows the customer to see a proof faster and, in turn, receive the die faster as well.

Hutchison: One of newest introductions to the market has been our NW SpeedChase® NTX™ for hot stamping, embossing and combination flatbed dies and pre-cast counters on a narrow web flatbed press. With this system, lock-up is reduced to one UniLock-Up® NW steel plate for engraved dies and another for pre-cast counters. Typically, job changeover is accomplished in mere minutes. The engraved dies are pre-mounted and pre-registered onto a UniLock-Up® plate and are ready for press right out of the box. Set-up and changeover can be done hot or cold. This lock-up technology uses magnetics and replaces the typical grid or honeycomb and includes an air ejector box to easily release the UniLock-UP plate from the chase. In addition, because of the smaller size of a narrow web chase, we can pre-set-up the counters as well. So, makeready is 80% complete when the dies and counters are received.

For offset applications, both small and large, we offer another system. The SpeedChase®, our air pneumatic magnetic chase, utilizes another type of UniLock-Up die plate. As with the narrow web system, all the engraved dies come pre-locked in register to the file supplied by the customer.

These systems have been a game changer, especially with foil stampers trying to find skilled operators and the labor shortage overall. It makes training simple and overall set-up much easier for the operators.

Rivera: One of our newer technologies for engravings is our NanoEmbossing effects. This technique provides amazing lenticular and photorealistic effects through H+M’s laser. This technique makes it possible to create textures that are up to 40% finer than standard micro-embossing effects, along with other effects that no other embossing technology can match. It is a perfect way to add a unique highlight to a foil stamped image.

Another product we offer is the EasyFix die lockup system to minimize set-up time on press, suitable for flat stamping, embossing and combo stamping. With this system, the dies are pre-mounted and pre-positioned on the plate and corrections can be made quickly to compensate for printing tolerances. Once the customer receives the plate, everything already is in place. It is a system for efficient set-up of foil stamping and embossing dies when there are several die positions on one sheet.

Other metallic decorating processes, such as cold foil transfer and digital foil processes, have continued to grow. How do you think this has impacted more traditional foil stamping and embossing applications?

Hutchison: I believe adding more decorative foil effects onto all types of printed work is great for the entire industry. No matter how it’s done, whether it’s cold, digital or hot foil decorating, they all have their place and have their correct applications. It is just about knowing when to apply each process and what jobs are best suited to a foiling process. An example of this is in the wine industry, where big-name brands were the primary ones adding foil. Today, due to machinery and other technological advances, there are smaller wineries that now can decorate their labels, too, with all the different foil decorating options available to them.

Schumacher: I totally agree. The more metallic enhancements that are out there, the more visibility there is. We have seen a decline in certain longtime hot foil jobs that have switched to cold foil transfer, but the overall pie is growing. All of us win. We now can reach a variety of different markets from small to large. Markets, such as wedding announcements, are adding metallics with digital enhancements, and these would have just been printed in the past.

The growth of CNC engravings continues. What are the advantages of CNC engraved dies and is there new technology now available in their manufacturing?

Rivera: Discussing CNC engravings, the longevity of the die is a key advantage. Another is the defined edges that help with the foil release to provide quality results of the stamped image. The other advantage of CNC is the ability to create a combination engraving to allow foil and embossing in one pass vs. two passes on press. Choosing CNC is design specific. It will continue to grow, technology wise, opening up even more possibilities.

Hutchison: CNC technology is a common manufacturing process and, in our industry, it typically is used to produce a brass engraved die. For our company, we manufacture both copper and brass dies, but we choose which manufacturing process best suits the customer’s needs and application. When brass dies are chosen, it often is based on the desired effects and/or duplicity of dies, among other factors – and we generally engrave these dies with a CNC. The metal itself determines the recyclability and durability. Brass and copper are similar, but an inherent value of CNC brass manufacturing is the ability to have precision and the ability to easily duplicate. Another benefit of CNC engraved dies is the use of interchangeable counters, meaning that if several brass dies (of the same image) are ordered, the counters can be interchanged. This provides cost-savings as well as reduces challenges.

Schumacher: For us, our CNC technology continues to improve and continues to grow. Years ago, CNC was limited in how dimensional it could get. We could achieve one to two dimensions and then we would finish the die by hand. But the CNC technology is much improved, and we can achieve more three-dimensional engraved images. This helps drive quality and consistency. We certainly are cutting more CNC dies that may have been cut by a master engraver in the past.

What type of recycling programs do you have in place at your engraving facilities?

Hutchison: At Universal Engraving, Inc., we recycle 100% of our scrap copper and brass metal. We also have developed a compliant process to remove the metals from our spent etching baths. In addition, we ‘internally’ recycle a large percentage of our etching bath back to our manufacturing process.

Schumacher: Our system at Metal Magic is 100% contained, so the waste acid is recycled by a certified recycler. We have zero discharge of hazardous materials – all copper/brass gets recycled, and we are diligent at recycling paper and plastic as well.

Rivera: H+M only works with brass engravings, so all the brass scrap and shavings are recycled. We have a recycling program for the entire facility at H+M.

Machine technology maximizes detail, eliminates chemicals.

By Hallie Forcinio, writer, PostPress

Computer numerical control (CNC) engraving is a process where a computer-controlled cutting tool is used to remove material from a workpiece to create a desired shape or pattern. This process has been around for several decades and has been widely used in the automotive, aerospace and manufacturing industries.

Advancements in technology have led to significant improvements in CNC machines and software, increasing the precision of the engraving process and helping to expand use of the technology for engraving sculpted embossing, combination foil embossing and foiling dies. The CNC machine can perform 100% of the engraving, although some dies still may be produced in a hybrid process that combines CNC engraving with hand finishing.

“The precision of modern CNC machines is measured in microns, allowing for extremely fine detail and accurate reproduction of designs,” said Christopher Arns, director of sales at H+M USA, a KURZ company, a supplier of hot-stamping and coating technology located in Charlotte, North Carolina. He explained, “This precision results in sharper and more accurate images with less ‘bridging’ or ‘flaking.’ This is particularly important in the decorating industry, where high-quality images and intricate designs are essential.”

Precise reproduction plus the sustainable nature of the technology will boost adoption of CNC engraving for the production of foil stamping and embossing dies, predicted Robert Murphy, vice president of sales and marketing at DATRON Dynamics, Inc., a supplier of CNC machines located in Milford, New Hampshire. The supplier is working with companies that want to bring engraving capability in-house.

Successful CNC engraving

Successful engraving depends on properly prepared artwork. “The three most important items needed for a quality CNC die are artwork, artwork and artwork! High-quality, 100% black and white vector art is crucial to creating a great die,” stated Doug Pendergast, national account director at Owosso Graphic Arts, Inc. Based in Owosso, Michigan, the photoengraver has been in business since 1949 and offers magnesium, brass and copper dies.

Engravers need to know all facets of a project, but first, and perhaps foremost, they must understand what substrate the die will encounter. “This will help ensure the correct depth and design is achieved for the specific application,” explained Arns.

In addition, “… clear communication with your engraver is critical,” said Ross Hutchison, president of Universal Engraving, Inc. and national sales manager of Infinity Foils, Inc., both part of the UEI® Group Companies, a supplier of foil stamping and embossing products in Overland Park, Kansas.

“Important details include the type of engraved die or tool needed, registration requirements, heat comp, press information, the number of dies needed, turnaround time, expectations, engraving perspective and finished intent, to name a few,” Hutchison continued.

When implementing CNC engraving, another consideration is identifying the right people to process the digital artwork and learning the best practices associated with operating the machine. “When purchasing CNC engraving equipment, it’s important to make sure it comes with proper training so die production can begin right away,” Murphy said.

Growth of CNC Technology

Brass, copper and magnesium can be engraved on a CNC machine. Photo courtesy of DATRON Dynamics, Inc.

CNC-engraved dies offer a sustainability benefit by eliminating the need for chemical etching and related environmental issues. “Engraving dies on a CNC machine is a cleaner process,” commented Murphy.

However, companies that decide to transition to CNC engraving should be aware they may need to install multiple CNC machines to achieve the same output as their chem-etch lines, which typically offer high-volume production.

The type of engraving and number of dies will help determine if CNC is the correct choice. There are many benefits to CNC, but the costs involved with the machinery, software and trained operators also must be a part of the equation. It is not the answer for all engraving applications.

Today’s CNC machines are more accurate and rigid and sometimes include integrated vacuum tables to hold stock material. In addition, cycle times are faster and, in many instances, CNC machines occupy a smaller footprint as well.

“The use of high-speed spindles, more powerful motors, advanced cutting tools and improved milling programs/strategies have significantly increased the speed of the engraving process,” Arns said. He added, “This increased speed reduces lead times and production costs significantly, which is particularly important in the graphic industry, where turnaround times are critical. With the ability to program and store designs digitally, CNC machines quickly can reproduce designs with a high degree of accuracy and consistency, reducing the likelihood of errors and ensuring that each product meets the same high-quality standards.”

“These features are vitally important to efficient production of quality dies,” agreed Murphy. Automated processes like an operator interface, which works like a smartphone, and control improvements using software simplify operation and provide step-by-step instructions for job setup and machine operation. Built-in safety features make the systems safe for virtually anyone to run.

“It takes three days of training to learn how to set up and run dies. Skilled machinists, who are difficult to find, are no longer required,” Murphy said.

At the front end, CAD/CAM systems used to process artwork and generate “tool paths” for a CNC engraver have become more powerful and easier to use, another time and cost saver. An array of engraving bits is available to achieve different effects. Bits can be resharpened multiple times and are inexpensive to replace when worn out.

Die materials and designs

Brass, copper and magnesium can be engraved on a CNC machine. However, brass is the most common metal for most engraving applications.

“Brass is a durable material and very easy to engrave. Brass can be engraved ‘dry,’ which means no coolant or lubricant is required,” Murphy said. “The brass chips generated by the engraving process can be vacuumed out of the machine using a shop vac and then recycled.”

Magnesium can withstand high temperatures and is impact resistant, which yields a long-lasting die. “Magnesium is used for embossing and combination dies instead of brass in some situations,” said Pendergast.

“CNCs can be used with any type of engraved die,” said Hutchison. “It is an operational decision that each engraver has to make – some engravers use only CNC equipment, and others don’t use it at all. We are a hybrid and have developed operational procedures that help us to determine which method of manufacturing is best for each order.”

Recent developments that rely on CNC engraving include new refractive MicroEmboss and NanoEmboss technology, which creates extremely fine patterns on the stamping die surface. Capable of adding a unique landscape of reflections, depth and dimension to the design, this technology is particularly well-suited for high-end packaging, luxury goods, cosmetic products and security applications. NanoEmboss and MicroEmboss dies do not require a fiberglass counter die and can be combined with emboss and combination dies. “The latest advancements allow MicroEmboss and NanoEmboss technology to be applied on cold foil,” noted Arns.

New technology advances have moved the art of CNC engraving forward, working with traditional engraving processes to offer more choice for those using dies to decorate print. Historically utilized in automotive, aerospace and manufacturing applications, it’s making itself known in die production for print and packaging.

Q&A on Foil Stamping and Embossing Engravings