The main printing techniques are screen printing, block printing and
photocopying. Letterpress, lithography, flexography, and gravure printing are
used in commercial manufacturing. Finishing techniques enhance the final
product.
Different packaging materials perform different functions. There is certain
information that must be provided on packaging by law.
Mechanisms are used for moving parts in pop-up books and cards.
Printing 1: screen printing, block printing and photocopying
Screen printing
The screen is made from a fine mesh material fixed to a wooden frame. A stencil is
placed under the screen and ink forced through the stencil onto the material below.
Screen printing with stencils is best for blocks of colour
Screen printing is used to print small runs of posters, display boards, fabrics, wallpaper
and control panels of electronic products.
Block printing
Indian block printing
Shapes are cut into blocks made of wood, metal or linoleum. Ink is applied to the block,
and the block is pressed onto paper.
Block prints can be quite detailed if the block is well made, but normally only one colour
is used. The process is good for making positive and negative images and repeating
patterns.
Block printing is used to print small and medium sized runs of greetings cards,
wallpaper, paper tablecloths and similar products.
Photocopying
Photocopiers can enlarge and reduce images, and process paper, card and clear acetate.
Different paper sizes can be used. They can also be used for back-to-back copying and
to collate multiple copies.
Colour photocopiers give good results but the copies are more expensive.
Photocopiers can be used to:

arrange multiple small drawings on a page

make multiple versions of the same drawing (eg to make a pattern)

enlarge or reduce drawings

copy reference material (if copyright allows)

copy artwork sheets to maintain a consistent style in a project folder
Printing 2: letterpress, lithography and gravure
These printing techniques are used in commercial graphics manufacturing, but they
require more expensive equipment.
Letterpress printing
Letterpress image courtesy of Justin Miller of Bound Staff Press
This is a form of relief printing. In relief printing, the parts to be printed are raised up
from the base plate. Letterpress printing can be used to produce both type and
illustrations. It is used for small printing jobs such as business cards and stationery.
Letterpress printing is becoming less common as it is time-consuming to set up the loose
type and make the plates, and the range of fonts and styles is limited.
Flexography
Flexography machine
Flexography uses a relief image on thin, flexible printing plates made of rubber.
Flexography can be used to print on materials such as cellophane, polythene and
metallic films, so it is often used to print plastic shopping bags. It is also used to print
newspapers and paperback books.
Lithography
A printing plate with a relief image is dampened with water and then coated with ink.
The ink only sticks to the parts of the plate that are not wet with water. The printing
plate is fixed to a roller and the image is transferred onto paper fed under the roller.
In offset-lithography, the paper does not come into direct contact with the printing
plate. Instead, the image is transferred to a rubber roller.
Lithography is used for medium and long print runs of products such as magazines,
posters, packaging and books.
Gravure
Image courtesy of Tim Lovelace
In gravure printing, the image is made up of small holes sunk in the surface of the
printing plate. The holes are filled with ink and any excess is removed. Paper comes into
contact with the ink in the holes when it is pressed against the plate.
Gravure printing is used for long, high-quality print runs such as magazines, mail-order
catalogues, packaging, and printing onto fabric and wallpaper. It is also used for printing
postage stamps and decorative plastic laminates, such as kitchen worktops.
Finishing techniques
Cutting and creasing
Some printed materials need to be cut or creased after printing. Cutting and creasing are
used when making packaging, pop-up books and cards, and press-out shapes for model
making.
Die cutting
Die cutting is used to make multiple, identical shapes.
It works in a similar way to a biscuit cutter.
A shaped blade called a die is used to cut material. The material to be cut is placed
under the die and the die is lowered.
For creasing, blunt blades are used. The blade does not cut through the material but
creases it. This is useful for materials that need to be folded such as surface
developments or popup mechanisms.
Cutting can also be done with a CNC cutter.
Other finishing techniques
The table below lists a number of finishing techniques that can be used on graphic
products.
Finishing techniques and their uses
Processes
Varnishing (water-based, oilbased, ultraviolet)
Uses

- Protection and enhancement

- Book covers and packaging
Cost
Low
Comment

- Easy process, but ink must be dry

- Water-based ink needs special
machine

- Oil-based is cheapest

- Ultraviolet very smooth, but ink must
be completely dry
Laminating

- Protection and enhancement

- Book covers, packaging and
special print jobs
Expensive

- Plastic film applied to the paper or
card on one or both sides

- Good for protecting products that are
handled a lot
Embossing

- Gives visual and tactile effect

- Business stationery, invitations
and packaging
Expensive

- Requires special press tools to be
made

- The shape is pressed into the paper
or card using steel dies
Foil applications

- Enhancement on special work
Expensive

- The design is stamped on the
material through a metal foil
Processes
Uses

- Book covers and photograph
albums
Cost
Comment

- This forces the foil into the surface of
the material