At present, aluminum caps are increasingly valued by enterprises because of their simple shape, low cost, good sealing and recyclability. The first step in creating a beautiful, high-quality bottle cap is the design. However, many designers only care about the aesthetics of the cap, and they don't know anything about the cap printing process. The designed product is not for production, or it is different from the idea.
In this paper, the author will start with the bottle cap printing process, analyze how to design an aluminum cap that is both aesthetically pleasing and meets the production requirements, and how to use a special printing process to achieve unexpected results.
Design software selection and design points
Design is the premise of printing. The color seen in the computer is very beautiful. It is not necessarily good after printing the finished product, so the printing factor must be considered in the design. The design drawing mode should use CMYK printing color.
1. Design software selection
(1) Photoshop
Photoshop is mainly used to process color images. The advantage is that it can display rich colors, convenient for retouching, and common channels for color separation modification. The disadvantage is that the produced image is composed of pixels, which is affected by the resolution of the image, and the image with smaller resolution is not easy to be sharpened after the image is enlarged, resulting in a sawtooth effect.
(2) CorelDRAW/Illustrator
CorelDRAW/Illustrator is used for the depiction of vector graphics. CorelDRAW is commonly used for drawing and typesetting of caps. The advantage is that the images produced are vector files, no matter how many times the magnification is enlarged, the edges are clear. The disadvantage is that it is not possible to retouch images when processing color images. In addition, the design files designed by the design company for customers are usually in Illustrator format, so it is also necessary to master the Illustrator software to facilitate the switching between the two softwares. The images made with Photoshop and Illustrator are shown in Figure 1.
It should be noted that when designing, the resolution is not as high as possible. This is because the resolution is too high and the file is too large, which is not conducive to image output processing and is prone to crash. Generally, the monochrome printing resolution is set to about 1200 dpi, and the color printing (ie, multi-color overprinting) resolution is set to 300 dpi.
(3) C4D/3Dmax
C4D/3Dmax is used for the production of stereoscopic renderings of caps. Stereoscopic renderings allow customers to see the design more intuitively and get recognition from customers faster.
2. Design points
The cap pattern is mainly divided into two types: side pattern stretching and side pattern rolling. The side pattern stretching cap is directly stamped and knurled after printing, which is a finished product. The advantage is low cost, and the disadvantage is that the pattern is easily deformed, and the requirement is not high. The winery is a good choice. The bottle cap of the side pattern needs to be stamped after printing the top and the side is printed again. The advantage is that the pattern is beautiful and not deformed, and the disadvantage is that the process is complicated, the time is long, and the cost is high.
(1) side pattern stretching
The elongation of the aluminum plate determines the degree of deformation of the side pattern, and the high quality aluminum plate will be more or less deformed. The higher the height of the cap, the more severe the pattern is deformed downwards, so try to put the pattern up and avoid knurling, slits, and spirals. It is recommended that the caps with a height of more than 35 mm be selected for the side scrolling process. Bottle caps with a height higher than 25mm should not be designed with a straight pattern. They can be designed as diagonal rows. The tensile deformation is not visible visually. The side effect of the cap is shown in Figure 2.
(2) side pattern printing
Attractive patterns in order to make the structured side, the top cap can first offset pattern stamped into the cylindrical bottle, then roll printing side. Rolling can print up to 6 colors at the same time. Unlike offset printing, although it can print a variety of colors, it is a variety of colors transferred to the rubber at the same time, so each color can not overlap, otherwise it will mix with each other. When calculating the side plane unfolding length, the outer diameter of the cap should be used, plus the length of the joint lap. The film used for printing is a negative type with the film surface below. The advantage of this process is that the pattern does not deform. The disadvantage is that the intersecting pattern has a joint and cannot print a color mesh pattern. If you want to print a color mesh pattern, you can choose the flexo process.
Common printing process and precautions
Aluminum cap printing is generally done by offset printing. At the time of printing, the dried PS plate is used as a master, which is printed on a flat aluminum plate by the principle of ink and water balance, and the color prints are formed by four times of CMYK four inks. Pay attention to the following when printing aluminum caps.
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