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Top Techniques for Using White Ink in UV Printing: What You Need to Know

In the world of printing, UV printing with white ink opens up new possibilities for producing high-quality prints on dark or transparent surfaces. On the other hand, it also introduces the need for meticulous art preparation and regular printer maintenance to manage the complexities of white ink. This guide will walk you through the essentials of managing UV printing with white ink, from setup and preparation to key considerations for achieving stunning results.

Understanding UV Printing with White Ink

  • Provide an Underbase for Color

    UV printing uses ultraviolet light to cure ink as it is printed. This process allows for precise and vibrant prints on a variety of substrates, including those that are challenging for traditional printing methods.   However, one limitation of CMYK inks is that they are somewhat translucent.  Printing a base layer of white ink below CMYK will allow colors to pop on dark substrates.  Otherwise, a dark substrate’s color would show through the CMYK image creating a dull appearance. 

  • Create Raised Textures

    The high opacity of white ink enables it to create raised, tactile layers. When applied multiple times in UV printing, it builds up physical texture on the surface, enabling designs to have a 3D effect that you can feel. By controlling the thickness of the white ink layer during the printing process, it's possible to create varying degrees of texture, ranging from subtle to highly pronounced. This control allows for a wide range of finishes and tactile experiences in the printed product.

Key Considerations for Managing UV Printing with White Ink

Ink Management

  • Ink Quality: Use high-quality UV white ink designed for your specific printer model. The consistency and opacity of the ink are crucial for achieving vibrant results.
  • Ink Composition: White ink contains titanium dioxide, which causes it to settle over time. To ensure consistent performance, shake the ink bags or bottles before the start of each day to re-disperse the titanium dioxide and maintain proper ink consistency.
  • Consistent Use: Regular use of the printer with white ink is necessary to prevent print head clogging. Even if you’re not actively
    using white ink, incorporate a small print on a test sheet to ensure the printer is functioning well. This practice helps avoid issues when you need to use white ink.
  • Storage: Store white ink in a climate controlled, dark place to prevent it from degrading before use. Proper storage extends the ink's shelf life and maintains its performance.

Graphic Design and Setup

Opacity and Density: Adjust the opacity and density settings of the white ink layer in your design software to achieve the desired
level of whiteness and coverage. The more opacity you use, the more accurate the color printed on top will be, especially when targeting specific PMS colors. Additional opacity can also be achieved by printing multiple layers of white ink.  For embellishments like a frosted look, use a lower white ink opacity blended with a low percentage of gloss to create the effect.

File Preparation: Use vector graphics or high-resolution images to ensure crisp and clear prints. Avoid using too many gradients or fine details that might not reproduce well with white ink. The RIP software will provide a seamless white ink workflow.  White ink can be selected as a spot color replacement, from Alpha channels within the design, or automatically generated by the RIP.

During the Printing Process

Choking the White Ink: Always "choke" the white ink during the printing process to prevent it from poking through when color is applied on top. This technique is often done in the RIP software, depending on its features. If your software does not facilitate this, ensure that you handle it through separate file preparation to avoid misalignment and color issues.

Printing on Dark Surfaces

White Ink as a Base Layer: When printing on dark or transparent surfaces, apply a layer of white ink first to create a solid background. This base layer will enhance the visibility and vibrancy of subsequent color layers.

Printing on Transparent Surfaces

White Ink as a Base Layer: When printing on transparent surfaces, CMYK ink may appear dull and less colorful.  Adding a white underbase will increase the vibrancy of colors.  If the material is backlit, you may also increase the amount of white for increased opacity and color density.

White Ink as a Top Layer or Backer:  When printing to glass or acrylic, often times the print is reversed and printed on the inside or what’s referred to second surface printing.  This method will require white ink to be applied as a top layer, over the reversed color layer, to create additional opacity to the color and to provide a smooth white exterior surface.

Printing on Textured or Porous Surfaces

White Ink as a Flood Layer: Many materials such as canvas or burlap may be a dull white and porous.  Both create a very muted unpleasant output without utilizing white due to both the white point and the porous material absorbing ink. Flood coating the material with a white underbase will allow the colors to pop by limiting the ink absorption and providing a bright white underbase for your graphics. 

Surface Preparation

Ensure that the surface is clean and free from dust or debris. Proper surface preparation helps in achieving a smooth and even white ink application.

Testing

Conduct test prints on the specific substrate to determine how the white ink behaves and make any necessary adjustments before proceeding with full production.

Printer Maintenance and Calibration

  • Regular Cleaning: White ink can be prone to clogging, so regular maintenance and cleaning of the printer’s print heads and ink delivery system are essential.
  • Calibration: Periodically calibrate your printer to ensure consistent color reproduction and accurate white ink application. This includes checking and adjusting the print head alignment and ink density.

Troubleshooting Common Issues

  • Ink Smudging: If you experience smudging or bleeding of white ink, check the curing process. Insufficient UV light exposure can result in incomplete curing, leading to smudging.
  • Uneven Coverage: Uneven white ink coverage can be due to improper ink application or substrate inconsistencies. This will typically cause a grainy or textured white graphic as opposed to smooth and even.  Ensure even application and consider adjusting the printer settings or ink density.  Consider an extra layer of white ink if necessary.  Adjusting the UV lamp intensity up or down will also change the look and feel of the image providing an additional option.
  • Banding: Banding in white ink often indicates missing nozzles. Always perform a nozzle check each day, and if any missing nozzles are detected, do not ignore them. Over time, it can become more difficult to unclog the nozzles, and a head replacement may be necessary, which can be costly. 

Ink Banding

Poor Nozzle Check

Conclusion

UV printing with white ink offers remarkable flexibility and opportunities for creativity, especially when working with dark or transparent surfaces. By understanding and managing the intricacies of white ink, from ink quality to graphic setup, you can produce high-quality, vibrant prints that stand out. Regular maintenance and careful preparation are key to achieving optimal results and unlocking the full potential of your UV printing capabilities.

Explore the possibilities of UV printing with white ink and elevate your print projects to new heights!

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