Flexo Technology Making an impression in printable
electronics and packaging By Tom Kerchiss of RK Print Coat Instruments.
P
rinters and converters that have navigated their way through the various financial crises and made the re-adjustments to their business plan, necessary as a result of the pandemic are more grounded in process and commercial reality than in the past. Looking to the future, today’s graphic arts practitioner, the labelling and packaging converter are looking to stake a claim and make an impression in product sectors and markets which as far as mainstream print processes are concerned are, relatively speaking new and untapped. Printed electronics and packaging for CE-marked electrical and electronic goods; two markets interconnected but with different and often contradictory requirements and objectives seems a good fit for flexo. Faster run speeds, new processing concepts, such as the flexo hybrid press and advancements made in consumables and in support technologies makes flexography competitive, and able to see off or at the very least compete with print processes such as gravure, offset and digital pose. Advances in fabrication techniques and the use of organic semi-conductors are the drivers of change, enabling inks to be deployed and for the printing of circuitry. Previously semi-conductor fabrication
required the deposition of slabs of semi-conductor films followed by the lithographic impression of the device structure and removal of surplus elements via chemical etching, etc. However, that’s changed. Redefined processing parameters, the creation and employment of organic polymers has turned a subtractive-based process based on the growth of films and selective etching into a more simplified and additive process, one that provides more freedom of choice. Flexible substrates can now be employed, while flexo with its roll to roll capability and speed of output lends itself to the production of flexible displays, bio-sensors, disposable electronics and even intelligent textiles, which would be more commercially viable than at present if flexo was used. Complementing the increase in production that flexo allows for, it also provides the resolution and precision that current and yet to be developed electronics will require.
Developments and a degree of refinement in performance critical components such as aniloxes and in consumables such as inks and other coatings have made a huge difference in quality and in customer expectations. Aniloxes with finer line screening and with a cell structure that need no
longer be confined to a hexagonal as well as inks that minimises dot bridging due to drying issues make flexo a more controllable process.
If one were to highlight an area of innovation that holds promise it would be flexo and digital hybrid technology. Early days yet, but the integration of digital inkjet as a process in its own right in with flexography to create a fully functioning hybrid system holds out great promise, particularly in niche applications such as the manufacture and print of electronics and electronic/electrical packaging. Hybrid systems may be worth considering in situations where flexo and digital on their own may simply not be practical or competitive. The amalgam of technologies enables the converter, working in conjunction with ink and other supply chain providers to print a highly decorative label or pack and then add variable digital information in a seamless operation. Hybrid presses, used where and when appropriate speeds production, enabling companies to bid for and obtain jobs that require a mix of digitized variable printed detail and stand out coloured images and blocks of colour needed for C-E marked electronic goods packaging and for other items.
With the tremendous variety of materials available, many of which require some consideration with regard to processing it is essential that product quality can be monitored and processing variables brought under control. Converters and product developers need to determine colour accuracy; they need to trial different formulations and run printed and coated materials off the production machine so that issues can be highlighted and resolved. Colour communication devices such as the K 303 Multicoater designed and developed by RK Print Coat Instruments is a versatile system for colour comparison purposes; it can be used to determine printability and adhesion. It is equipped with interchangeable gravure and flexo heads as well as meter bar coating and can be accessorised with bars for making wet coatings from 40500 microns.
The VCML Lab/Pilot Coater is also an option. With a working web width of up to 300 mm and offering short run capability the VCML can print, coat and laminate on all types of flexible substrates. It can be configured for clean room conditions (a requirement for many electronic components); it can be ATEX zone protected and major print and coat head
technologies can be integrated in with the system.
Xwww.rkprint.com
28
February 2022
www.convertermag.com
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