Category 13: Functional printing

gold winner - AUTO DIAL

PROTOLAB ELECTROTECHNOLOGIES PVT. LTD

Auto dial is used in Automotive cluster for 2 wheeler vehicles and has backlit illumination in night condition. The chaplets and text are
illuminated and it is important to morph the article to achieve uniform illumination. The illumination is used to improve the look and visibility of dials.

COUNTRY:
India

PRINTING TYPE:
Screen

PRINT VOLUME:
50000 nos

TECHNIQUE:
This dial is processed in 4 ups with 1 mm Polycarbonate sheet 470 mm x 400 mm with 11 color passes/impressions plus one pass/ impression of varnish on the top surface and 4 colors printed sub surface. All inks are solvent inks and after each pass/impression ,it is jet dried and baked. Subsurface printing and one over print UV lacquer for the LCD window /display.

EQUIPMENT:
Semi automatic printing machine - Grafica make- Nano - 560mm x 710 mm print area with manual
vacuum table.

TIME FRAME:
On a average the machines are working with average speed of 200 impressions/hour, hence
daily 4000 impressions in 3  shifts. The batches are 5000 sheets x 14 impressions= 60000
impressions. Total 4 machines are engaged for the same and average process time is 5 days for a production run of 20000 parts.

C13 Shortlist 3.PNG

It is used on the front fascia of a hybrid PCB based Membrane switch used in medical application. It is used in X-Ray machine and as they require tactile feed back as well as
embossing for the keys. We proposed the design with 3 D graphics for visual appearance
as embossing reduces the life of the overlay as various harsh cleaning and sterilizing reagents are used for cleaning the X-Ray department.

COUNTRY:
India

PRINTING TYPE:
Screen

PRINT VOLUME:
500 nos

silver winner - Membrane switch

PROTOLAB ELECTROTECHNOLOGIES PVT. LTD

 

TECHNIQUE:
This membrane graphic is processed in 2 ups with a Polyester 2V 150 material sheet having dimension 470 mmx 370 mm printed with 19 color passes/impressions. All inks are solvent inks and after each pass/impression dried and baked..

EQUIPMENT:
Grafica Printing machine with manual vacuum table.

TIME FRAME:
The screens are processed in 2 ups and the batch size is 250 sheets with 19 impressions. It is
printed on a manual vacuum table and the process time is 250x19 = 4750 impressions with a average rate of 120  impressions/hour which is 1200
impressions /day and hence the process time is 4 days with one operator.

bronze winner - Premium Package -Glenfiddich

Keetronics(India) Pvt Ltd

This year at FESPA-2018, We are excited to present a Smart Package which is Premium, Classic and has something new which has not
been presented before. We are presenting Premium Package -Glenfiddich. This package
consists of three parts and uses three different technologies. In the first part we have integrated
a Capacitive touch sensor which is Screen printed and the circuit is powered by battery. When you
hold the package, the integrated LED glows. The Second part of the package is Electroluminescent
(EL) display. This EL display is placed at the bottom of the package which adds more value to
it and makes it more Premium. Electroluminescent Display is developed by printing different layer of materials like Silver, Phosphor, Dielectric, Transparent Conductive, protective layer, one
upon the other and driven by a voltage using batteries. Every Whisky is identified by its age
and this is one of the important parameter for the consumer. To send across this information
every Whisky package has the Age printed on it. To convey the Age of the Whisky, We have used an innovative way which makes consumer interact with the package. This is achieved by Third and most interesting part called Dualistic
Printing. This is the text beneath the brand name GLENFIDDICH. At your first look, you might notice two question marks ( ?? years old ). But
when you lift the package, the question marks turns to number 18 which is age of the Whisky.
Here we have used a special technique to print these text using Roland LEF-300 Digital Printer.
When illuminated from behind, it changes the text as required. These technologies/ techniques give
numerous opportunity for the designers to think out of the box and use these value additions to
increase the Brand Value and get their product into the Premium Class.

C13 shortlist 2.PNG

COUNTRY:
India

PRINTING TYPE:
Mixed (combination of printing techniques)

TECHNIQUE:
The package is produced in 3 steps. The graphic printing is done using Roland LEF-300 UV inkjet printer on 350GSM Cardsheet. The sheet is then
laser cut into the required shape. The capacitive sensor circuit is printed using Atma Flatbed screen printing machine on 125 micron PET substrate. The inks used are conductive silver ink and dielectric ink from Henkel. The components for the capacitive sensing are mounted using Arraycom’s low temperature solder paste. The
LEDs from Edison-Opto are also mounted using the same solder paste. The Electroluminescent
display is printed seperately, also on PET. It consists of 5 layers viz. transparent conductive, phosphor, dielectric, conductive silver and encapsulant. The EL is also printed using Atma flatbed screen printing machine and inks from Norcote Inc. The EL is driven by an inverter which
is controlled by a push switch. The “18 Years Old” text is printed on 100 microns PET substrate
by strategically arranged layer sequence and controlled opacity to get the 2-way view effect. All the layers were then sandwitched using 3M double sided adhesive.

EQUIPMENT:
Designing - CorelDrawX7 Printing - Capacitive sensor circuit, EL panel - Atma Flatbed screen printing machine; Graphics on cardsheet - Roland
LEF-300 with EcoUV inks  conveyer IR drier
(Natgraph) Nano-UV curing machine - (Graphica
flexotronica) Laser Cutter (Silicon laser systems) Digital UV Inkjet printer (Roland LEF-300) TWS conveyer drier

PRINT VOLUME:
Being a proof of concept/prototype this was
produced in 3 Nos.

TIME FRAME:
The project was completed in 3 weeks which includes the designing, printing and assembly part.