Intro to Foils

Foil stamping is a popular method of relief printing, allowing foils to be transferred to a surface with heat and pressure using metal etched or engraved 'dies'. Hot stamping foil is unique in being able to offer bright, mirror-like, metallic finishes. During the stamping process, the foil creates a slight impression into the material, which creates a level of luxury that is unachievable through digital print. There are four main types of decorative foils available to you on the market; Hot stamping foil, Die-less / Cold foil, Digital and Textile foils.

When selecting the correct type foil you should always consider the substrates, foiling methods and machinery. When selecting a type of foil there are various considerations you should take into account. The material that is being foiled will determine the grade of the foil you select. Machinery should also be taken into account as specific foils work better with certain machines. For example, some substrates require foils that operate at high temperatures or high levels of pressure.

There are many different foil finishes to choose from so choosing the correct one to match your project requirements is important. Using specific foil finishes can add subtle enhancements to cards, product boxes, posters and more. Standout foils such as holographic, fluorescent and brushed effects can create added impact.

Fine, Medium and Solid are the terms used to describe the definitions that can be found within foiling. Different details require different foils in order to achieve the best result possible. Generally lower temperatures should be used for finer details and higher temperatures should be used for large solid areas.

The structure of the substrate is important especially if the substrate is textured or uncoated as these will require foils with thicker adhesives. You should also take into consideration the opacity because using fluorescent, pearlescent and some pigment foils can alter the appearance of foils on darker substrates.

Choosing the right die material can massively improve the outcome of your project. Two of the most commonly used materials are Magnesium and Brass. When selecting a die material you must weigh up both the pros and cons for each. You should consider substrate, artwork and the production run length as these are important factors.

Choosing the correct makeready material is important as they will result in the following benefits; a reduction in set-up time, an improvement of the overall quality of the foil print, allows crisper definition when foiling fine text and details, ensures greater consistency and a higher quality finish throughout short and long-run print jobs.

Selecting the right machinery is crucial as it is important to ensure your investment(s) in machinery is worthwhile and suitable for the print/finish you require. The choice of a foiling machine will also depend on the type and size of the items to be foiled and the output speeds required for that particular work. A good quality machine will allow you to adjust the following three variables; pressure, dwell time and temperature.