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Industry Decorating Methods

Debossing
The image is depressed into a material such as paper, leather or suede, so the image sits below the product surface. Ink may or may not accompany the stamp (color stamping).

Decal Transfer
A water-soluble decal, printed on an offset or letterset press, is submerged in water and slid onto the product to be imprinted. The decal is rubbed with a cloth or squeegee to remove any excess water and air from between the product and the decal. The product is then kiln-fired. Once fired, the decal becomes fused with the glaze. Hairline registration and superior reproduction of detail make it an excellent choice. This imprint withstands washing very well. This method is labor intensive, since each decal must be aligned and applied by hand. Used when many colors and tight registration are desired on less than perfect porcelain, ceramic and glass products.

Die
A mold into which molten metal, plastic or other material is forced to make a special shape, such as pen barrels or rings. Also a tool made of very hard material used to press a special shape into or onto a softer material such as coins and emblems.

Die-casting
Molten metal is injected into the cavity of a carved die (a mold).

Die Cutting
The use of sharp steel blades to cut special shapes from printed sheets.

Die-Stamp
Steel plate engraved with desired image used to "stamp" (apply) gold or silver leaf.

Die-striking
A method of producing emblems and other flat promotional products. A blank, cut from a metal sheet, is struck with a hammer that holds the die.

Die-Struck (Die-Stamp)
A die is used to press an image into a softer metal such as brass or gold. The die is put into a press, and the press is released and actually squeezes the metal into the recess of the die making the imprint on the metal. The height of detail is not as deep as casting; the letters and images are shorter. Fine detail and deep images cannot be achieved because the lines and gullies in the die may break during the striking process. Used in metals such as medals, coins and belt buckles.

Embossing
Stamping an image on a material, such as paper, leather or suede, so the image rises above the surface of the object. As in debossing, ink may or may not accompany the stamp.

Embroidery
A design stitched onto a material through the use of high speed, computer controlled sewing machines. The design is reproduced with tightly-stitched thread. Embroidery is most commonly used on logo patches and directly on some wearables. Fine detail is difficult to achieve.

Engraving
The cutting or etching of designs or letters on metal, wood, glass or other materials. There are three engraving techniques. hand-engraving, hand-tracing, and computerized laser engraving. Engraving is performed with a diamond point or rotary blade that cuts into the surface of the product. Engraving offers a permanent imprint that will not wear off because it is cut into the metal base. Used in metals such as trophies, pens and nameplates.

Etching
The product to be imaged is coated with a resist (a protective coating that resists the acid). An image is exposed on the resist, usually photographically, leaving bare metal and protected metal. The acid attacks the exposed metal thus leaving the image etched into the surface of the metal. Very fine lines can be reproduced by this process and the only tooling is a piece of film, so spec samples are easily-made.

Flexography
A flexible rubber plate is wrapped around a cylinder for speed and control. As the paper moves under the printing plate, it is pressed against the printing plate by another roller, and the ink is transferred onto the paper. A separate plate is needed for each individual color. Typically done on less expensive materials than screen printing. The inks are very thin and not as durable as those used in screen printing.

Four-Color Process
The reproduction of full-color artwork through the combination of four process ink colors – magenta (red), cyan (blue), yellow and black – in specified intensities. Colors are separated into individual color plates so that when printed in register, they produce a full-color illustration. Four-color separations refer specifically to the process colors: magenta, cyan, yellow and black.

Halftone
The reproduction of a continuous tone artwork (such as a photograph) done by filtering light through a screen that converts the image into a pattern of dots of varying size.

Heat Transfer Printing (Direct Transfer Process)
Image is screened on a transfer substrate which is then laid directly on the material to be imprinted. The image is then "transferred" from the substrate to the material through the use of heat and pressure. Works best on cotton and cotton blends.

Heat Transfer Printing (Sublimation)
A process in which a design is transferred to a synthetic fabric by heat and pressure. The heat causes the inks to turn into a gas so that they penetrate the fabric and combine with it to form a permanent imprint.

Hot Stamping
Method is which type or designs in the form of a relief die are impressed with heat and pressure through metallic or pigmented foil onto the printed surface. It is used to decorate fabric, leather, paper, wood, hard rubber, coated metal and all types of plastic. Hot stamping is a "dry" imprinting process meaning the object can be handled immediately after the stamping without fear of smearing the imprint.

Pad Printing
A recessed surface is covered with ink. The plate is wiped clean, yet the ink remains in the recessed area of the plate. A silicone pad presses against the plate and pulls the ink out of the recesses. The pad then moves and presses directly against the product. Pad printing is excellent for imprinting small, unusually-shaped objects for which screenprinting is not practical. Small watch dials and cylinder shapes are some examples. This is not the most highly-recommended process for imprinting large areas; screen printing is better for large areas of ink coverage. Used in plastics, paper, ceramics, glassware, wearables, leather and vinyl.