Hologravure

By Jachin Wang

This book is the author's dissertation on Development Hologravure for Production in United States for the degree of PhD requirements in business administration.

• Language: English
• Publisher: Xlibris US
• Release date: Jan 12, 2016
• ISBN: 9781514410974

Jachin Wang

Jachin Wang was former research and development management of Perfect Plastic Printing Corporation in Illinois (1990–1999). Plant improvement of Imperial Wallpaper of Wickes Furniture Co. in Indiana (1982–1990). Quality Control manager of China-Gulf Plastic Corporation in Taiwan (1872–1981). Chief IE of Nan-Ya (Formosa) Plastic Corporation in Taiwan (1961–1971). He received his BS degree of chemical engineering from Chung-Yuan University. His thesis, “Quality Control in-processing for rigid vinyls lamination,” for degree of master of science. A dissertation, “Development Hologravure Production in the US,” for the degree of PhD in business administration of Kennedy-Western University in California. He was prior to join the faculty in practical research and development for “Hologravure” from exclusive process available only Perfect Plastic Printing to production in U.S. on April 03, 1992. Hologravure Diffusion International (HDI) gave the exclusive using the multi-dimensional printing processes produced initial in U.S. An another patent is called “Lenticular Lens” (3-D) in U.S. on August 06, 2001 which were listed his name as an inventor too. (The Patent No. 6,277,232). “Hologravure And Lenticular Lens” both are known process of producing multi-dimensional printing processes lithographic imaging which impart the illusion of depth and (or) motion to a viewer. Typically lithographic images are created by using a series of individual still picture created from photographs or other artistic works which are segmented and then merged together in a desired this sequence to form a composite picture or image. Dr. Wang’s research and development in printing processes, color measurement and management, new product development, team approach continuous improvement with more than thirty-eight years experiences in manufacturing of plastic industry, especially in the new technologies of three-dimensional printing processes of “Hologravure and Lenticular Lens” development and production. He can be reached at [e-mail]

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Copyright © 2016 by Jachin Wang.

Library of Congress Control Number:   2015919894

ISBN:      Hardcover      978-1-5144-1165-0

                Softcover        978-1-5144-1164-3

                eBook             978-1-5144-1097-4

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the copyright owner.

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Certain stock imagery © Thinkstock.

Rev. date: 06/10/2016

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CONTENTS

Chapter 1. Hologravure in General

1-1: Photorealistic Hologravure

1-2: Definition of Hologravure

1-3: Illusions Of A Multidimensional Universe Appearing Plastic.

1-4: Lamination offers many benefits to Hologravure.

1-5: Technology Development Today. (see More detail in Chapter 10)

1-6: What is a Hologravure

Chapter 2: Hologravure in Graphic Art Photography

2-1. Negative and Positive

2-2: Color Reproduction

2-3: Optic Screen Plate making for Hologravure

2-4: Scale for Hologravure

2-5: Copy for Hologravure

2-6: Speedmaster 74 D1 of Heidelberg

Chapter 3: Basic Raw Material For Printing Of Hologravure

3-1: Rigid vinyls compound.

3-2: Calendering (Sheet or Film Forming)

3-3: Management's role in plant of Calender line.

3-4-: Rigid Vinyls Film / Sheet Specifications:

3-4-1: Rigid Vinyls Overlay Stock:

3-4-2: Rigid Vinyls Clear / White Corestock:

Chapter 4: Printing And Printing Inks For Hologravure:

4-1: General Printing Process For Hologravure.

4-2: Printing process in Hologravure.

4-3: Digital Printing In Hologravure.

4-4: Offset and Screen Printing Inks and Inks test.

4-5: Color management for Hologravure printing.

Chapter 5: Lamination for Hologravure.

5-1: Laminating Presses and their systems.

5-2: Laminating press frame.

5-3: Polishing Plates.

5-4: Lamination Press Platens:

5-5: Heating And Cooling System.

5-6: Lamination monitoring system.

5-7: Steam Generators:

5-8: Polishing Plates In Laminating Process:

5-9: Thermal Pads In Lamination Process.

5-10: Conclusion: Management in Lamination production.

Chapter 6: Optic Screen Making For Hologravure Printing.

6-1: Materials and Tools for making optic screen of Hologravure

6-2: The principle types of fabrics.

6-3: Recognized screen fabrics.

6-4: Non-Moire's Screen Making For Hologravure.

6-5: Preparation of screen fabrics.

6-6: Exposure processing.

6-7: Screen Emulsion (or applying Capilex film.)

6-8: Developing of optical screen.

6-9: Blockouts of optical screen.

Chapter 7: Screen Printing Of Optic Clear Lines For Hologravure

7-1: Basic Press Categories Of Screen Printing.

7-2: Ink drying equipments of screen printing.

7-3: Silk Screen Printing

7-4: Optic Screen Printing Ink

7-4: Optic Screen Printing

7-5: New development in screen printing ink to improve environmental issues.

7-6: Durability of silk screen printing:

7-7: Corona surface pre-treatment.

7-8: Post Press Gross Clean Procedure:

7-9: Screen Reclaiming Procedure

Chapter 8: Managerial Control In Production Of Hologravure.

8-1: A profitability plan and cost control.

8-2: Financial Control

8-3: Cost Control Of Quality.

8-4: Zero Defects Programs:

8-5: A practical management method to measure color in printing.

8-6: Team managers for problems solving in-processing.

Chapter 9: Team approach continuous improvement in production of Hologravure.

9-1: Principles of operation management in Hologravure.

9-2: System Alignment: Presentation Guidelines

9-3: Define The System

9-5: Operational Definition

9-7: Stabilize The System

9-8: Plan For Improvement

9-9: System Alignment (Deming Circle) Review:

Chapter 10: Digital technologies developed for Hologravure in future

10-1: Different types of scanners and their functions:

10-2: Digital Technology Development In Twenty-one Century.

10-3: The Internal Computer In The Laser Printers.

10-4: Digital Printing Has Already Taken Over.

10-5: Digital systems of quality control in manufacturing process for production:

10-6: Conclusion

Appendix

Bibliography And Reference

Preface

Hologravure today neither common sense nor very popularity be known to all-men. It can't find out in any textbook or dictionary, but people were known Holography, it is a lens-less photographic method that use laser light to reduce the three dimensional images by splitting the laser bean to two bean and recording on a photographic plate the minute interference pattern made by the reference light waves reflected directed from a mirror and the waves modulated when simultaneously from the subject of the virtual image can be reconstructed by shining laser light and white light through the developed films. What has related between HOLOGRAVURE AND HOLOGRAPHY? A very simple definition is: Interference by speckle is the HOLOGRAPHY. But interference by MORIE' of the density is the HOLOGRAVURE. or interference by MORIE' is the HOLOGRAVURE. this' very basic principle to determine between HOLOGRAPHY and HOLOGRAVURE. the speckle is produced by DOTS of the printing plates, but the MORIE' is formed by lenses.

I was prior to joint the faculty in practical research and development of Hologravure from exclusive printing processes to produce three-dimensional image available only of Perfect Plastic Printing Corporation in United States on April 03, 1992. the HDI-Hologravure Diffusion International gave us the exclusive using this 3-D technologies of printing process (initial basic technical knowledge) continuous developed to apply and transferred to production of high security credit cards in U.S.A. An another 3-D of patent is called Lenticular Lens in US on August 06, 2001 which was listed my name as an inventor, the patent no. 6,277,232. The 3-D of HOLOGRAVURE AND LENTICULAR LENS which both are known in printing process to produce the multi-dimensional images including lithographic process and silk screen printing process which impart the illusion of depth and (or) motion of 3-D to a viewer, the lithographic image are created by using a series of individual still picture created from photographs or other artistic works which are segmented and then merged together in a desired this sequence to form a composite picture or image.

I was worked on research and development in plastic printing process, color management, new product development, team approach continuous improvement with more than thirty-eight years experiences in the plastic manufacturing industrial, especially in the three-dimensional images of rigid plastic printing for high security credit cards production technologies. This book former was also my dissertation of Development Hologravure For Production In United States for the degree of Ph.D requirements in Business Administration. You can reach me at [e-mail].

Chapter 1. Hologravure in General

At the present time, you can find some three dimensional images in common commercial they are: general decoration of hot stamping foil, micro-metallic super-shining foil, 3-D Christmas card, 3-D credit card, 3-D calendar, 3-D photo-image of CANON COMPANY OF JAPAN, 3-D movies and showroom in Chicago Museum of Science and Industry or Disney world. It is include: 3-D Lanticular, 3-D Hologravure, micro metallic foil, three dimensional camera and large space 3-D of showroom.

1-1: Photorealistic Hologravure

In may, 1996. Mr. David Scher stated Because of photorealistic interference and density, CD printing relies on high halftone line counts and a high mesh count Thus the potential for MOIRE is great. To print halftones of more then 100 lines per inch. CD decorations depend upon a screen with extremely high mesh counts. As this chart shows, no mesh is currently available that will support halftones of Than 132 lines per inch without creating MOIRE.

In hologravure, MOIRE produces at least 120 lines per inch which directly effects Photorealistic image. And the images of the photorealistic relate to clear vinyls of plastic sheeting in regards to its thickness. (See next page) the picture show on the lower thickness of clear vinyl plastic sheet must be increased lines per inch; 12 mil thickness of the clear vinyl plastic sheet must be increased lines to 200, 16 mil of thickness clear vinyl plastic sheet need at least 180 lines per inch and 20 mil thick of clear vinyl plastic sheet the lines total 175 only.

The printing of photorealistic of hologravure is a difficult process. Because the process raises concerns about factors such as inks usage, conventional inks and UV curable inks of four-color-process, the availability of suitable ink system (concern solution density and temperature) and control system of Litho printing, the viscosity control system on the silk screen printing. Stencil selection and durability, the availability of a suitable screen match (195 screen mesh and 390 mesh screen will be used) and mesh tensioning (100 to 150 NT) requirements. In the process control to satisfy all these requirements. To achieve a three Dimensional photo image, a number of the screen printing factors must be addressed.

(A). The main procedure include:

(1). Preparing artwork and separations: Basic on original product's design according to customer's requirements. After finishing original design of the image then to transfer into production practical in-processing. The design is not a dream idea, it must be consideration in-processes can able to easy production in timing, lower cost and high quality.

(2). Selecting and preparing the screen: Usually 390 mesh to select for 175 -- 350 lines per inch need and very special to make a screen with out any MOIRE (big to small MOIRE). It must be following special technical of Hologravure procedure. Furthermore detail in next chapter.

(3). To create the stencil: in three dimensional must be created stencil to meet 3-D requirements. It means to create clear the dots lines and Hologravure solid lines.

(4). To select the inks: the conventional inks and UV curable inks both are acceptable in Litho printing and Silk Screen Printing.

(5). Setting up the press: the photo dots is 100% solid according to the original design's quality requirements. To set up the press must be closed enough the dots density after printing in the Litho printing. And the solid lines on Silk Screen printing to meet such as lens to reflecting the light.

(B). Graphic of Hologravure starts with high quality original art design:

(1). First the original art is scanned at twice the lines count of the half tone screen and then printing.

(2). Second the original art is mixed with other graphic elements, it is including the dots lines and the solid lines.

(3). Finally the original art of the image is prepared for output as a halftone separation on the film.

(C). The proper mesh types:

The proper mesh type and thread count are of great important, one factor is the mesh color. UV curable inks in Hologravure print are generally provided ready for use. After selecting mesh and preparing the high tensioning screen. A stencil must be created, four types of stencil system are available. Indirect film and direct combined film and emulsion systems or capillary film both can be selected.

(D). Lines per inch

In general reading distance around 18 inches dots that are 75 lines per inch -- lpi or smaller are blended into smooth colors, even this disappears at 133 lpi or higher, less 75 lpi almost everyone can see the dots with the naked eye. But the another factor is controlling dots size, if the dots were any smaller than 65 lpi, they plugged up in the shadow and disappeared in the highlights.

Usually the dots lines range with different applications:

The addition, the finer the dot is the higher cost. Ultrafine screens for dots require better equipment, better facilities, better technology personnel and more time, but in most cases, screen finer than 175 lpi used in Hologravure printing are not effective cost.

(E). The shape of dots.

In generally digital dots are all square, but halftone dots can be any shape. However within the usable realm a variety of dot shapes have definite utility. There are five dots are using in different printing products, they are: (1). Round dot. (2). Square dot (3). Elliptical dot. (4). Lines dot. (5). And Shape dot. In Hologravure printing normal the shape dot will be used.

(F). Thickness of clear PVC sheet.

In Hologravure printing the thickness of plastics clear sheet is direct effective three dimensional light. The picture showed the thickness of clear PVC sheet is 20 mil the dot lines must be within 175 lpi. If the thickness reduced to 16 mil of clear plastic sheet, the dot is increasing to 180 lpi. Finally if thickness reduced to 12.mil, and dot must be increased 200 lpi.

Thickness Of Clear PVC Sheet And 3-D light

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PVC.jpgDICO.jpg

DICO LINES DETERMINER

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(G). The dots lines.

The line always connection by dots, a straight line is the shortest distance between to Point. In Hologravure printing always the lines are straight but maybe many groups of straight lines are different angle only. In postscript lines are called paths and are defined by dots point.

(H). The shape.

A line is called a path in PostScript, this path is a purely one dimensional shape, the line has length but without width or height. When a path goes back to the original point and connects the last point with the first point, it become a closed path, it is called shape.

(I). New abilities in PostScript- Transformation.

A very special thing of the amazing about PostScript shape is that it can transform the shape to create into almost anything. The basic transformation tools are rotating, flipping, scaling, and skewing. When combined with point editing, cloning and the duplication of transformation virtually anything can be done.

(1). Rotating: Any shape or any line included a group of lines and shapes can be rotated with extreme precision. A line can be cloned and rotated 11,75 degree around a clicked point. it can duplicate this transformation 14 more times to produce an 16-sided circular border etc.

(2). Flipping: The flipping tool takes lines, shapes or group and flips them horizontally, vertically both or at any angle.

(3). Scaling: This transformation allow to change the size of anything, either proportionally or not, around any center proportionally changing line.

(4). Skewing: To take any shape any distort it by moving and or rotating one or more side relative to the other. When necessary it can skew a shape into perspective.

(5). Cloning: To select line, shape or both and to make an exact duplicate in the same location.

(6). Duplication transformation: The transformation or combined transformation can be repeated infinitely until run out of time, space, memory or any patience.

(J). Printing registration of accuracy for printing.

Generally the printing accuracy called registration. Registration refers how consistently the sheet feeds whether change size. The size is affected by (1). Printing machine designed accuracy. (2). Temperature control system. (3). Humidity of the printing environment. And (4). The printing operation included rollers pressure etc.

(1). Printing tolerance:

The common tolerance of registration is a half-dot. Example: if printing within 150 lines per-inch, or printing allowed 300 lines per-inch, if it is out of register by more than that can be rejected by customers.

(2). Duplicators of printing requiring.

Duplicators are very basically eliminated from entire category of printing required tight registration, though duplicators cannot handle the quality needed but digital presses can. The presses are low-resolution, the machine structure enables to hold the half-dot tolerance.

(3). Processes colors (ink issue) affective registration.

An image assembly is needed for hairline registration spot color work, commodity. This is a six or seven color, process color technology. One of the first difficulties is that many colors cannot be reproduced by equipment at hand. If the printing the image can be finished at one time, it is a simple process more accuracy. But if the printing process is complexity required more time to complete, the registration will be off, it means accuracy is reduced.

1-2: Definition of Hologravure

Hologravure is an interference by MOIRE and line density. The MOIRES (small or Big MOIRE) and line density (one hundred twenty to three hundred fifty line per Inch) directly effect the results by many reference factors and limited conditions. They are: the film density is limited within twenty to fifty-six, every inch of the line Is 120 to 350 lines per inch. The difference is due to the different color film but the film density is limited within 20 to 56. the optical lens must be within one hundred to one hundred seventy five lines per inch, and line angle must be limited within 30 to 60 degree.

The MOIRE size ranges from small to big, the cross lines differ in angle with the Different film emulsion types. All of above is a simple optical and mechanical Principles. The optical lens will be printed on the top of the image of the clear rigid vinyl plastic sheet.

MS%2018.jpg

16-20 Mil Thickness Of Clear Plastic Sheet

1-3: Illusions Of A Multidimensional Universe Appearing Plastic.

A space-age-electrode lightningbrush printing application and meticulous craftsmanship were fused to create this interesting laser painting by Mr. Dave Archer. It has been enhanced with Hologravure, an exclusive process available only at The Perfect Plastic Printing Corporation in the U. S. It use a new patented system which requires no foil or special hot stamping. The images are reproduced using conventional printing ink and four-color-process UV curable inks. These surface are like no other and actually seem to