Engineer Training
Lesson 1.8
Substrates
Context
Engineer Training
 What are the printing substrates?
 Materials frequently used on signage market, their properties and
applications.
 Materials leading brands.
 Substrates for Superjet.
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What This Presentation Gives You
Engineer Training
 Knowledge about materials used by
our customers.
 Knowledge about customer
applications and why they use a
specific material for certain
applications.
 In the bottom line: better
communication with customers,
understanding their needs and
problems.
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Introduction
Engineer Training
 Substrates with paper liner (top cover)
 Corrugated (fluted) carton
 Compressed carton
 Foam board
 Plastic substrates
 Polycarbonate
 Foam PVC
 Acrylic
 Polypropylene
 Aluminum Composite Materials
 Polystyrene
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Carton
Engineer Training
 What is liner? Types of liner.
 What is flute?
 Most popular flutes for FB6700 (E, B, C, EB, BC). Thickness
depends on flute type.
 Compressed (non fluted) cartons.
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Examples
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Main Features of Carton
Engineer Training
 Cheap
 Easy to fabricate and mount
 Light weight
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Main Applications of Carton
Engineer Training
 Packaging
 POP
 Trade show booths, 3 dimensional shapes
 Displays
 Exhibits
 Presentations
 Models and prototypes
 Signs
 Theater pops
 Window displays
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Foam Board
Engineer Training
Foam board consists of polystyrene/polyurethane foam bonded
between various high quality papers.
It is available in a wide range of sheets size and thickness.
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Examples
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Made from Kapa Block
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Main Features of Foam Board
Engineer Training
 Easy to fabricate and mount
 Light weight
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Main Applications of Foam Board
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 Picture framing and mounting
 POP
 Displays
 Exhibits
 Presentations
 Models and prototypes
 Signs
 Theater pops
 Window displays
 Trade show booths, 3 dimensional shapes
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Plastics In the Beginning
Engineer Training
 The first product called Celluloid was created as the first
commercial plastic. (1868)
 The first photographic film was Celluloid (1882).
 In the 1920’s, the big progress in development took place with
the introduction of Vinyl and Nylon.
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Polycarbonate
Engineer Training
Polycarbonate sheets are as transparent as glass, but 200 times
stronger while weighing 50% less. They provide the answer to
virtually every covering and glazing application.
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Examples
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Examples (cont.)
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Multi Wall Polycarbonate
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Multi wall polycarbonate sheets combine the superior
characteristics of polycarbonate with the advantages offered by
multi-wall design. This yields a light, strong, insulating, and
attractive sheet for varied roofing, cladding, glazing, and other
applications.
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Examples
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Examples (cont.)
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Examples (cont.)
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Main Applications
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 Safety glazing
 Protective shields
 Bus stops and telephone booths
 Roofs for building
 Stadium roofing
 Skylights
 Transparent sound absorbing barriers for highways
 Street advertisement lighting boxes
 Can be transparent or opaque
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Foamed PVC
Engineer Training
Foamed PVC sheets are ideal for indoor and outdoor use in
advertising, construction, and industry. PALIGHT sheets feature
lightweight, durable, and versatile surfaces, which can be
painted, printed, laminated, embossed, engraved, or milled.
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Examples
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Examples (cont.)
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Examples (cont.)
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Examples (cont.)
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Main Features of Foamed PVC
Engineer Training
 Half the weight of rigid PVC
 Same thickness at lower cost
 Good mechanical properties
 Easily worked with conventional tools
 Low water absorption
 High chemical resistance
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Main Applications of Foamed PVC
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 Advertising – signs, displays, and exhibition boards.
 Construction – models, interior decoration.
Air conditioning ducts, etc.
 Industry- control cabinets and panels, structures for corrosive
environments, etc.
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Acrylic Materials
Engineer Training
Came to the market in 1936.
Acrylic is an extruded high quality acrylic sheet. Acrylic is more
transparent than glass. Its inherent UV resistance makes it ideal
for outdoor applications. Acrylic sheet can easily be formed,
shaped, sawed, routed, and drilled.
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Examples
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Examples (cont.)
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Main Features of Acrylic
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 Transparent – above 90% light transmission
 Inherently UV resistant
 Stronger than glass
 Light weight
 Easily formed and fabricated
 Easy to mount
 Good chemical resistance
 Good thermal insulation
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Main Applications of Acrylic
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 Glazing
 Signs
 Light fixtures
 P.O.P. displays
 Fabrications
 Thermoforming
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Polypropylene
Engineer Training
Corrugated twin-wall sheets, made from a polypropylene
copolymer resin
 Lightweight
 Strong
 Durable material
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Examples
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Examples (cont.)
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Main Features of Polypropylene
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 Durable and long-lasting, yet flexible
 FDA approved material for the food industry
 Flame retardant
 Resistant to water and dampness
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Main Applications of Polypropylene
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 Retail, real estate, yard signs
 P.O.P. Displays
 Trade displays
 Greenhouses
 Mail boxes
 Toys
 Packaging for food
 Decorator panels
 Awnings
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ACM (Aluminum Composite Materials)
Engineer Training
This is a lightweight but rigid and durable aluminum composite
material (ACM) — two strong sheets of .012" aluminum bonded
to a thermoplastic core.
The surface is coated with polyester.
This weather-resistant material is ideal for a wide range of
signage and exhibit/display applications.
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Examples
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Examples (cont.)
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Examples (cont.)
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Main Features of ACM
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 Easy to fabricate and install
 Versatile, complementary designs
 Durable, rigid material
 High weight to strength ratio
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Main Applications of ACM
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 Interior and exterior signage
 Exhibit/display
 Point-of-purchase displays
 Awnings
 Store fixture applications
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Main Applications of Polystyrene
Engineer Training
 Insulation
 ID cards
 Decals
 Signage
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Polystyrene (ABS)
Engineer Training
ABS is an amorphous resin. It is manufactured by combining
three different compounds: acrylonitrile, butadiene, and styrene.
There are different grades for injection molding, extrusion, blow
molding , foam molding, and thermoforming.
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Examples
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Examples (cont.)
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Main Features of Polystyrene
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 Good tensile strength
 Dimensional stability
 Surface hardness
 Rigidity
 Heat, chemical, and abrasive resistance
 Good impact strength
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Main Applications of Polystyrene
Engineer Training
 Different goods – TV and computer monitors, automotive trims,
electrical enclosures
 Toys
 Packaging for cosmetics, food, consumer appliance
 Signage
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A Lot of Brands on the Market
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 Foam PVC – Komatex, Sintra, Forex, Palight, Celtec
 Foam board – Kapa, Bienfang, Fome-Cor, Gatofoam
 Acrylic – Perspex, Optix, Implex, Plexiglas
 Polypropylene –Coroplast, Polygal, Corex
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Substrates - Self Adhesive Vinyl
Engineer Training
Vinyl is a layered, plastic-based substrate, constructed as follows:
 Paper or fabric is covered with a thin layer of silicon, onto which an adhesive
is applied.
 A layer of PVC is added; all are heat-fused.
Advantages:
 The PVC surface is water resistant, very flexible and strong.
 Dryness and humidity do not affect the vinyl’s flatness.
Disadvantages:
 The PVC surface can be a problem when printing with water-based ink
(surface tension).
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Substrates - Self Adhesive Vinyl
Engineer Training
structure
Image
PVC
Silicon
Adhesive
Paper/fabric/Plastic
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