Screen Printing

The resolution of screen printing depends primarily on factors such as the mesh count of the screen, the quality of the photosensitive emulsion, and the precision of the equipment. Under ideal conditions, screen printing can achieve the following levels of detail:

• Line width:The finest particle size can reach approximately 50μm (0.05mm).
• Line spacing:Minimum spacing is approximately 70~100μm

This makes screen printing highly competitive in creating intricate lines, micro-patterns, and functional layers. Especially when roll-to-roll screen printing equipment is used with a precise alignment system, it can reliably reproduce high-detail designs and is often used in the production of high-occlusion, fine patterns such as light guide layers for touch panels, optical decorative films, and even piano black finishes.

Screen printing is best suited for vector and high-resolution image formats, featuring clear lines and color separation in the design data. The following are common and recommended file formats:

• AI (Adobe Illustrator):The most common vector format, which facilitates subsequent color separation, editing and output.
• PDF (editable):It has high versatility and can also be used as an output template if the vector properties are retained.
• EPS:Supports vector graphics and color separation, suitable for professional printing processes.
• PSD (Photoshop):For image-based designs, a resolution of 300dpi or higher is recommended, and the layers and printing areas should be clearly marked.
• TIFF / PNG:Limited to monochrome or simple designs, and requires high resolution (300~600dpi or higher).

Precautions:

• It is recommended to use the CMYK mode or provide the correct Pantone spot color (special color) to facilitate ink color separation.
• For functional coating applications (such as piano black, light-blocking, light-guiding layers, etc.), the function and thickness requirements of the area must be specifically specified to facilitate corresponding process settings.
• It is important to note that the thickness of the pattern should not be less than 0.2mm, otherwise the ink may clog the screen, resulting in an unsatisfactory printed pattern.

Sage provides customized artwork development and technical support, covering everything from texture design to printing testing. If the customer provides the design, we will assist in the review and provide optimization suggestions to ensure that the screen production and coating quality are optimal.

Roll-to-roll screen printing, through continuous automated control, can effectively improve the production stability and consistency of functional coatings. Specific methods include:

• Stable tension and speed control:
  By utilizing a sophisticated automatic tension control system and synchronous drive motor, the material is kept uniform and flat during transport, reducing wrinkles and positioning errors. It is particularly suitable for functional film processes that require high alignment accuracy.
• High coating thickness consistency:
  With high-resolution printing rollers and stable doctor blade pressure control, the coating thickness can be kept consistent each time, avoiding the impact on product performance due to uneven coating.
• Online quality monitoring:
  Through modules such as infrared drying and visual inspection, the coating effect and positional deviation of each section can be monitored in real time, and abnormalities can be eliminated immediately to improve the overall yield.
• Reduce human error and changeover time:
  Roll-to-roll systems reduce downtime for material changes and increase automation levels, significantly reducing operational uncertainty and the risk of human intervention.

Sage leverages the advantages of roll-to-roll screen printing in functional coating applications to ensure the stability and consistency of precision coatings such as piano black coatings and light-blocking layers, meeting customers' demands for high-quality functional films.