FORT WORTH, TX—The lights dimmed. The triumphant horns played a familiar tune. The iconic lines scrolled across the screens: “A long time ago, in an industry far, far away…” But this wasn’t a Tuesday morning showing of Star Wars: The Force Awakens—it was the beginning of the final session of day three of Forum 2016. Direct Laser Engraving: Yesterday, Today and Tomorrow was chaired by Johnny Stamey, Daetwyler and Steve Smiley, SmileyColor & Associates and featured a panel of speakers who gave their thoughts on where DLE has been, where it’s at and where it’s going.
The seven person panel consisted of:
- Cris Apley, business development manager at Cyber Graphics
- Brian Cummins, director of North America flexographic laser technologies at K. Walter
- Paul Zeinert, direct engraving manager at Anderson & Vreeland
- Nick Brunk, divisional sales manager for micro 3D printing & packaging at Kodak
- Hans Siebke, worldwide application specialist for HELL
- Brendan Pollard, managing director at Applied Laser Engineering Ltd. (ALE)
- Adam Smrdel, director of flexography at Carey Color
Apley, who has spent 30 years in the flexo industry, spoke about the steady improvements of engraving media. Present day options, he said, include consistent end to end diameters, a near eradication of low spots and improved surface finishes. “The multitude of compounds and durometers can meet practically every printer’s needs, however specialized,” Apley stated. In the future, he predicted the advantages of DLE will make it an appealing choice to not just continuous printing applications, but all printers.
Cummins, who has a 24 year work history, opened with a description of his workflow from “a long time ago”: Stretching a rubber plate and stapling it to a wooden cylinder. “Things are changing” he stated, pointing to new compounds, laser technologies and software. A call back to Monday’s session, Cummins hailed direct engraving as a game changer for printers, because it is “simplicity at its best.” Looking to its future, Cummins said further advancements like the ability to engrave up to a 5,080 resolution will continue to pique printers’ interest, which will cycle more development dollars into the technology, which will improve DLE more and attract more attention.
Zeinert, who has a three decade career with Anderson & Veeland, opened by declaring direct engraving “the flexography dream.” He added that it allows for greater control over pressure, can mitigate halos and hold smaller type. Looking to the horizon, Zeinert said he “believed it’s something that will be here.”
Brunk, also with 30 years of graphic arts experience, spoke fourth. He asked a seemingly hypothetical question to the audience: What if you could run the press faster and longer, reduce changeover times, achieve outstanding quality, have complete control over plate dot structure, withstand aggressive inks and substrates, and enjoy excellent ink transfer? The allure of DLE is real, because, according to Brunk, “It’s not your father’s rubber engraver.”
He added to the chorus of previous speakers in singing the praises of DLE, adding that its use also comes with significant environmental benefits, because the traditional exposure and processing steps are eliminated. Brunk also said to expect improvements in the next five years to throughput, quality and consistency of elastomer sleeves and plates.
Seibke, a 25 year veteran, followed Brunk. “Why am I excited about direct laser engraving?” he asked. In short, he said it is a simple process, also singling out its high tonal range and durability. Envisioning the DLE of tomorrow, he hopes for a boost in performance, coming from faster machines as well as faster material. In certain applications (flexible packaging, tubes, etc.) Seibke believes it will become the industry standard. And he says the DLE of the future will compete with rotogravure.
Pollard, who has a four decade relationship with DLE, spoke to some evolutions he has experienced first hand, like CO2 and fiber laser technology. In the next 40 years, Pollard said he expects to see greater productivity, shorter pulse lasers, different colored laser beams and greater choice for printers.
The final speaker was Smrdel, who has worked at Carey Color Inc. since he turned 16. He recalled some of the evolutions he has seen as a way to frame his urge to find what’s next. A prolific author for FLEXO Magazine, Smrdel highlighted the material covered in his five past articles, which touched on topics like elastomer vs. photopolymer, gray component replacement (GCR) and under color removal (UCR), press profiling, elastomer advantages and holding a KISS impression, and thermal contraction and expansion.
“I have seen a very steady growth of engraved elastomer material—both through finding solutions not possible with other materials and by word of mouth between printers sharing their positive experiences,” Smrdel declared.
Opening the discussion of DLE to the entire panel, Stamey and Smiley prompted various speakers to talk about laser types, what materials can be engraved, the unique characteristics of the image carrier’s design, whether or not other press components need modification, when to optimize, benefits of DLE and what the future holds.