Silk-screening or printing labels on either aluminum or plastic enclosures

[derGoldstein]

I've been looking into ways to print labels on plastic and aluminum enclosures. In the case of aluminum I can't laser-etch those because it will probably have a layer of lacquer on it, and also because some enclosures would require specific colors.

I've seen this process be used in many documents and videos:


It seems to be exactly the process used for the silk-screening step of PCB manufacturing. When the dye is on the surface, it either gets heated up, or exposed to UV light to cure.
Does anyone here have experience doing this "at home"? All of the google results come back with silk-screening fabrics (mainly t-shirts).

I found this video on how a machine/rig used to silk-screen on fabric can be used on metal:


Sorry if this post sounds like a "google this for me" question, I'm just trying to get a feel of whether this process can realistically be done at home, or if I should be looking either to send the enclosures off to a facility, or to maybe use some other process entirely.

[Cerebus]

Definitely doable at home. I was screen printing stuff at home when I was a kid, that's how difficult it is. Obviously using photostencils is a bit more complex that what I did at age 7, but the most difficult bit about it is probably going to be  finding somewhere convenient to wash screens out.

You may even be able to find a local art centre or adult continuing education centre that has the equipment and the tutors to teach you how to use it. Their emphasis might be fine art, but the basic technical side is identical whether you're producing art posters, t-shirts or front panels.

The only thing that may be somewhat problematic is tracking down the right kind of inks in the sort of quantities you'll want to buy. The last time I went hunting these kind of inks down the smallest size I could find was 5 litres.

[jmelson]

You should also look at what this outfit offers :
https://www.vpcinc.com/

I use their products to make panel labels.  Of course, now, I see that it is being discontinued!  Damn!  This happens to everything I use!

Anyway, the old stuff had a vinyl base sheet that had adhestive on both sides.  The film was exposed with UV light and then pulled apart from a backing.  You then put the film over the base, and it adhered image-side down, leaving the top a strong plastic layer.  I could then laminate this to the aluminum panel and cut out the various holes in the panel for switches and connectors.  See

http://pico-systems.com/mbps.html

for a picture of one unit using that technology.

Their new stuff (quick-Mark Digital) seems like it will be fairly similar, except that you don't need the UV lights.

Jon

[jmelson]

So, now that I find (to my horror) that VPC is stopping production of their UV-exposed Quick-Mark technology, and a quick scan of the net turned up nothing similar, I have to figure out what to do!

So, this stuff I've been using for about 20 years does this:

I make a negative image on silver litho film with my laser photoplotter.  I contact print that negative onto  the Quick-Mark film and separate that film from the dye layer.  This gives me a positive image sheet in the color of my choice, with the words reading right and the image on the BACK of the film.  I then laminate that to their base sheet, stick that down to the aluminum panel and cut out holes for switches and connectors.  Kind of a tricky process, but makes a NICE-looking, very durable panel.

Does anybody know of any other outfit that has something that you can do yourself?  The idea is a self-stick material with the printed label laminated BEHIND the front sheet.

What I think I could probably do is take VPC's digital film over to FedEx Office and have them print on that with a color laser printer, and then do as always with the laminating.
One plus with this process is I can have multiple colors on the panel.  A possible problem is FedEx may not want me putting some untrusted material into their printers.

Thanks in advance for any suggestions!

Jon

[JPlocher]

Would inkjet or laser printing in reverse onto transparency mylar be an alternative? 

  -John

[ChrisLX200]

Quick-Mark Digital seems to offer similar functionality to the UV kit - from what I read anyway, not that I've tried either

https://www.megauk.com/quickmark-digital.php

[jmelson]

Would inkjet or laser printing in reverse onto transparency mylar be an alternative? 

  -John

Well, I think this is what VPC's new Quick-mark Digital stuff does.  You print with a laser in reverse on the back of the top sheet, and then laminate to the base sheet.
But, you need a really good printer for it to look good.  My good printers only have black toner, and my color laser printer ALMOST works.  But, FedEx Office does have some good printers.

I won't use inkjet, as most inkjet ink will fade.  The gear I sell is expected to be used for 20 years or more.  Hopefully color laser toner will last longer.

Jon

[voltsandjolts]

Too much faff.
Just laser print onto Avery Heavy Duty labels. They work brilliantly.
If you need ultra-super-duper durable then place a self-adhesive clear sheet on top.

https://www.avery.co.uk/water-resistant/water-resistant-labels

[jmelson]

Too much faff.
Just laser print onto Avery Heavy Duty labels. They work brilliantly.
If you need ultra-super-duper durable then place a self-adhesive clear sheet on top.

https://www.avery.co.uk/water-resistant/water-resistant-labels

But, I can only print in black!  I have been using blue lettering on a white panel label for years, and want to stay with that.
This is for low-volume gear that sells for several thousand $ per unit, so i want it to look good, and don't have a problem spending a few $ on the label.

Jon

[DerekG]

But, I can only print in black!

You can print in any colour if you have a Fuji Xerox wax printer

If you need to print some nice brochures etc, these are great printers that are quite cheap to run. They do use some wax every time you turn them on, so we print some brochures at the same time to make it worthwhile.

[voltsandjolts]

Too much faff.
Just laser print onto Avery Heavy Duty labels. They work brilliantly.
If you need ultra-super-duper durable then place a self-adhesive clear sheet on top.

https://www.avery.co.uk/water-resistant/water-resistant-labels

But, I can only print in black!

Eh? The labels work perfectly with a colour (color) laser printer to print any graphics you like.
I use this range of labels with either white or silver background:
https://www.avery.co.uk/water-resistant/water-resistant-heavy-duty-labels

[jmelson]

Too much faff.
Just laser print onto Avery Heavy Duty labels. They work brilliantly.
If you need ultra-super-duper durable then place a self-adhesive clear sheet on top.

https://www.avery.co.uk/water-resistant/water-resistant-labels

But, I can only print in black!

Eh? The labels work perfectly with a colour (color) laser printer to print any graphics you like.
I use this range of labels with either white or silver background:
https://www.avery.co.uk/water-resistant/water-resistant-heavy-duty-labels

I have a dumpster color laser printer that probably won't work any time I turn it on without an hour of fiddling.
I have 2 plain laser printers and only black toner.  I'm NOT going to go out and buy a color laser printer so I can print 5 panel labels a year.
The old Quick-Mark stuff I used would make labels in any (one) color I chose from a black and white original.  Since I have a 1000 x 1000 DPI laser photoplotter, I used that as it was more dimensionally accurate than a laser printer, and also gave better contrast.

So, I was just reaching out to see what options I have available.

Jon

[voltsandjolts]

...I could probably do is take VPC's digital film over to FedEx Office and have them print on that with a color laser printer...

OK, so just to be clear, you have decided that this is not an option now?

[jmelson]

...I could probably do is take VPC's digital film over to FedEx Office and have them print on that with a color laser printer...

OK, so just to be clear, you have decided that this is not an option now?

Well, I still have some of the old VPC UV-printable material left.  When it is all gone (or expires) then I will have to get some of this new Digital stuff and try it out.
It IS cheaper than the UV stuff, so that is a plus.  So, it is the ONLY option that I think is likely to work "out of the box".  By that, I mean that VPC has a whole package of materials to do it.  If I try to make up my own solution with combining transparency film from Co. A with double-sticky base material from Co. B, there could be compatibility issues that might not show up for a year.  As I mentioned, this is expensive gear that I don't want to have problems with down the road.

I do know how their existing UV material lasts, and it is VERY good.  I'm not sure, but I think I've been using it for almost 20 years, and the panels still look like when they were new.

Jon

[apelly]

Can't find the original thread, but found this post by the amazing robrenz:
https://www.eevblog.com/forum/chat/front-panel-methods/msg190373/#msg190373

[janekm]

To go back to the original question, yes I've done silk-screen printing of enclosures "at home", it's a bit of a faff but can be done. It's easy to order the silk-screen stencils. The process is similar enough to t-shirts that you could probably use that as a starting point 

The vendors of the screens and inks will be able to give you some suggestions and pointers too.

However, I'm confused by your premise... you said that your aluminium is going to have lacquer on it, which seems strange, as usually you would anodize aluminium (like an iPhone) which will give a very durable finish and is a great base for laser engraving?

[voltsandjolts]

...I could probably do is take VPC's digital film over to FedEx Office and have them print on that with a color laser printer...

OK, so just to be clear, you have decided that this is not an option now?

Well, I still have some of the old VPC UV-printable material left.  When it is all gone (or expires) then I will have to get some of this new Digital stuff and try it out.
It IS cheaper than the UV stuff, so that is a plus.  So, it is the ONLY option that I think is likely to work "out of the box".  By that, I mean that VPC has a whole package of materials to do it.  If I try to make up my own solution with combining transparency film from Co. A with double-sticky base material from Co. B, there could be compatibility issues that might not show up for a year.  As I mentioned, this is expensive gear that I don't want to have problems with down the road.

I do know how their existing UV material lasts, and it is VERY good.  I'm not sure, but I think I've been using it for almost 20 years, and the panels still look like when they were new.

Jon

Apologies, I didn't make my point clearly enough.
You derided my suggestion because you don't have access to a colour laser printer but had previously stated your willingness to use the colour laser at FedEx Office.
It's hard to help someone who is being inconsistent.

[jmelson]

Apologies, I didn't make my point clearly enough.
You derided my suggestion because you don't have access to a colour laser printer but had previously stated your willingness to use the colour laser at FedEx Office.
It's hard to help someone who is being inconsistent.

I'm certainly NOT deriding anything, and not trying to be inconsistent!

At the extremely low volume I do this stuff, I have no problem using the FedEx Office printers, ** IF **  they will let me put this stuff in their printers.  That may be the only sticking point.
But, it has to come out looking VERY good, so a really good printer in tip-top shape is needed.

So, when the need arises, I will try to get a sample of the stuff from VPC and do a trial run.  If FedEx is OK with printing on this material, I suspect it will work well.

Jon

[DerekG]

** IF **  they will let me put this stuff in their printers.  That may be the only sticking point.

If the box says the contents are safe to use in a laser printer, then they will usually say OK. If not, then you will have to find another way.

[derGoldstein]

However, I'm confused by your premise... you said that your aluminium is going to have lacquer on it, which seems strange, as usually you would anodize aluminium (like an iPhone) which will give a very durable finish and is a great base for laser engraving?

I'm not sure if it's a lacquer, it's a clear coat layer added after sealing ( http://aluminumsurface.blogspot.co.il/2009/04/why-sealing-process-is-so-important.html ).

So the aluminum doesn't look and feel like a "regular" anodized surface where you can pass a fingernail over it and feel tiny ridges (and even their direction if it's brushed). It's more shiny and smooth.

Maybe it could be laser-etched, but it's a very resilient finish and I'd rather not mar it. Also I need more than one color.

[janekm]

However, I'm confused by your premise... you said that your aluminium is going to have lacquer on it, which seems strange, as usually you would anodize aluminium (like an iPhone) which will give a very durable finish and is a great base for laser engraving?

I'm not sure if it's a lacquer, it's a clear coat layer added after sealing ( http://aluminumsurface.blogspot.co.il/2009/04/why-sealing-process-is-so-important.html ).

So the aluminum doesn't look and feel like a "regular" anodized surface where you can pass a fingernail over it and feel tiny ridges (and even their direction if it's brushed). It's more shiny and smooth.

Maybe it could be laser-etched, but it's a very resilient finish and I'd rather not mar it. Also I need more than one color.

You can get a shiny, smooth finish in "regular" anodized aluminium btw (see the jet black iPhone 8 for an impressive example), though it'd be quite expensive due to the extensive polishing required.

I don't imagine you'd like to apply a plastic label to your product as that would obviously not be very durable so I think your main options left are silk-screen printing and UV exposed ink (like used for PCB solder mask). The latter may be a little easier, getting a good print with silkscreen printing needs a bit of practice. Both would need to be tested for compatibility with your base lacquer.

BTW there are plenty of service providers out there which can do it for you, usually they are in the business of customising promotional items. They will often have a kind of inkjet-style printer using UV cured inks as well allowing them to do very small runs (but you may not like the rasterised appearance).