Preparing Pad Printing Files: Preventing Overlooked Issues with Uneven Ink Coverage and Crushed Small Text

When manufacturing industrial parts in Thailand, design files submitted for Pad Printing plate production may result in uneven ink coverage in solid areas or small text becoming crushed and unreadable after printing. These issues can require operators to spend additional time correcting the artwork and may affect the production schedule. This article explains how understanding the limitations of the printing process and the required conditions for setting up 2D files can help control the amount of ink according to the specified requirements.

Table of Contents

• Plate structures that cause uneven ink coverage in solid areas and fine lines
• Adjusting etching depth and adding halftone patterns to maintain ink coverage
• Fine-line and white-out text sizes to consider before Pad Printing
• 2D file setup conditions used as checkpoints before plate production
• Supported file formats and image resolutions for plate production
• How Tokuabe (Thailand) can help
• Frequently Asked Questions
• Key terms for understanding this article

■　Plate structures that cause uneven ink coverage in solid areas and fine lines

When a plate design contains both fine lines and solid areas, using the same plate depth throughout makes it difficult to control the amount of ink. If the ink amount is adjusted to suit the fine lines, the solid areas are more likely to show uneven ink coverage. Conversely, if the ink amount is adjusted to suit the solid areas, the fine lines may experience ink bleeding. The difference in ink drying time between these two areas is one factor that can cause uneven color on the printed part. This issue should be considered from the initial file-design stage.

■　Adjusting etching depth and adding halftone patterns to maintain ink coverage

One method of reducing uneven ink coverage is to make the etching depth in solid areas shallower, thereby reducing the difference in ink drying time compared with fine lines. For large solid areas, adding a halftone pattern can help the ink remain more stable on the pad. In addition, adding an outer border of approximately 0.1mm can help smooth out jagged edges caused by the halftone pattern, producing a sharper outline and a more uniform appearance across the printed area.

■　Fine-line and white-out text sizes to consider before Pad Printing

Pad Printing has limitations when reproducing very small lines. Reviewing the 2D data according to the specified requirements therefore provides a basis for preventing missing or broken lines. The minimum line width should be at least 0.1mm so that it can be transferred onto the part. White-out text should be at least 0.15mm to reduce the risk of ink flowing into the open spaces, which can cause the characters to become crushed or filled in and therefore unreadable. Adjusting the size according to these values helps control the clarity of the printed result.

■　2D file setup conditions used as checkpoints before plate production

When submitting 2D data for the production of a Pad Printing plate, there are basic conditions that engineers and designers should use to assess the accuracy of the file, as follows:

• Create the file at an actual-size scale of 1:1 and set the unit to millimeters (mm)
• Convert all text to outlines (Create Outlines) to prevent font distortion
• Clearly define the plate etching area (Etching Area), separating the design from dimension lines
• Check the file format, color mode (CMYK), image resolution, and small details before submission

Reviewing these conditions during the file-preparation stage can help reduce back-and-forth checking and allow the plate production process to proceed according to schedule.

■　Supported file formats and image resolutions for plate production

Before submitting the file, the file extension and resolution should be checked against the specified requirements to prevent pixelated images or the need to spend additional time correcting the data. General images should have a resolution of at least 300dpi, while logos or barcodes should use a resolution of at least 1200dpi. The file formats that can be used for plate production are as follows.

File formats supported for Pad Printing plate production

■　How Tokuabe (Thailand) can help

Tokuabe (Thailand) produces Pad Printing plates based on customers' 2D file data. We conduct an initial check according to the specified requirements. If line widths are too thin or the spacing between characters is too narrow, we can assess the file and make preliminary adjustments to suit actual printing conditions. The required conditions for review are a 1:1 image scale, outlined text, and a clearly defined etching area. If these conditions are incomplete, please contact us for further information.

※For more details, please download the PDF file attached to this article or contact us by completing the form below.

■　Frequently Asked Questions

Q1：Can 3D data be used to produce a Pad Printing plate?
A1：3D data cannot be used directly for plate production because the Pad Printing plate production process is two-dimensional. Plate preparation therefore requires 2D data at actual size (1:1). 3D data can be used as supplementary information to evaluate the shape of the part.

Q2：Why is converting text to outlines a required condition before submitting a file?
A2：Converting text to outlines helps prevent font changes. When a file is opened on a different computer or device, outlining converts the characters into graphic shapes, allowing the layout to remain unchanged and helping prevent production errors.

Q3：What is white-out text, and how does it affect Pad Printing?
A3：White-out text refers to leaving the character area transparent while printing a solid color around it. If the size is smaller than 0.15mm, ink may flow into the open space, causing the characters to become crushed or filled in and making them unreadable when printed on the actual part.

■　Key terms for understanding this article

• Etching Depth : The depth at which the design is etched into the Pad Printing plate. It affects the control of ink volume and ink density.
• Halftone : A fine mesh-like pattern added to solid areas to help the ink adhere to the pad more consistently and reduce uneven ink coverage.
• Outlining : The process of converting text into graphic shapes to prevent character distortion when the file is opened on different devices.

※For more details, please download the PDF file attached to this article or contact us by completing the form below.