Project planning and overview

The sophistication of Embossing

To make your printed work really stand out, a number of options are available. Hot Foil printing, spot varnish thermography and Embossing are a few that come to mind, however nothing does the job better than the sophistication and elegance of Embossing. There are several types and finishes that can be created by Embossing in almost any shape and texture imaginable.

Want your printed materials to look and feel different to others, look no further than Embossing.

Important Notes:

• When Embossing and or debossing, it is important to make the distinction between registeredand blind. Registered refers to Embossing and or debossing done in registration with a foiled or printed image. Blind refers to Embossing and or de-bossing done on a random area or a non-print area.

• When selecting paper, colour, coating, texture and weight all play a key role in the look and feel of an Embossed item. For projects where intricate designs need to be Embossed, thick uncoated paper or board will reveal the greatest detail in the Embossed image. You are able to achieve good quality Embossing on thinner materials but will be limit by the depth of the Embossing before the paper will cut/split.

• Creating an accurate Die can be very difficult without detailed information of what’s being Embossed.

Data required for Die making include:

• Data on the type of substrate being used.
• The thickness of the substrate.
• The run length.
• The depth of Embossing.
• The look and affect you need to achieve.
• The type of Counterforce required.
• and more…..

This information should be supplied with the Die manufacturing order to allow for correct Die creation. For multi-level and combination Dies, colour-coding the various levels in the image design in the file will ensure accurate Die making. Ensure a colour code Key is supplied with data of the different depth and effects each colour represents. In addition, an image of the top and side view of the Die showing what you require will help in the Die making process.

• Dies made out of Brass are recommended as they are very durable and are able to create high quality and intricate designs on them. Brass Dies can be engraved using CNC engraving (milling) machines, manual engraving machine or can be hand chiselled to create 2½ and or 3D sculptured Dies. If designed imaginatively these Dies could produce exquisite detail to make your product come alive and stand out from the crowd.

• It is essential that proper electronic files are created in the formats required by the Die making department or company, when ordering Foil Stamping and or Embossing Dies.

• When sending files for manufacturing Foil Stamping and or Embossing Dies, ensure the artwork does not contain any information within it that you don’t want engraved or etched on the Die. This includes any information on colour, masks, screens etc.

• When e-mailing or sending electronic files, it is important that you convert all the fonts to outlines. The outline of a font is all that’s needed when creating Dies for Foil Stamping and Embossing. Most high end design applications have the option to convert fonts into outlines. In Adobe Illustrator, you have to select the Create Outline option for every font in the file. To avoid the possibility of errors, always include “key” information about each font, such as point size, font name and any other attributes.
  All scanned images should be at the highest resolution and, if the file includes scanned artwork, it should be no less than 600dpi resolution. A low resolution scan may result in a blurry image, with its lines and edges feathery and inaccurate. Ensure all images are in black and white, as colour or greyscale images may result in lower quality, increase cost and longer turnaround times.

• When saving files, always save at 100% scale and indicate if the image is right reading or not. There are a number of graphic applications such as Corel Draw, Adobe Illustrator, Photoshop, Quark express and many more and numerous file formats like Jpg, Tiff, PDF etc. Contact your Die maker or Die department for information on how they would prefer the file to be created, saved, sent etc. They will provide information on the programs they have, what file extension they would require, and any version compatibility issues. Good communication with the Die maker or Die department will greatly reduce mistakes and delays.

• Where ever possible always send hard copy proofs of any electronic files sent, whether that be by, courier, messenger, post, fax or any other means. This helps to verify that the data sent in the electronic file is accurate and so prevent nasty surprises!

It is important to remember that Embossing Dies can be made as a single-level or multiple-level Die, depending on the complexity required. A combination Die is required if Foil Stamping and Embossing is to take place in one combined pass through the press.

To enhance the Embossing effect, Foil Stamping is sometime added to the process thus creating a striking effect. However when the substrate is Embossed and has no embellishments such as foil or printing on the raised surfaces, it is referred to as Blind Embossing. If the blind Embossing project is designed effectively, it will project a high degree of style and sophistication.

The best Embossed work is usually created from a detailed Die and a thick paper substrate, which combined with the skill of the designer and the machine operator, can produce amazing results. Since Ink, foil, substrate, Die and colour selection are all important elements in the success of an Embossed or Foil Stamped project, it’s a good idea to get the Foil Stamping department or company involved in the project at the design level. Furthermore, before beginning any project where Hot Stamping foil is being used, talk to you foil supplier and similarly to you Die and Counterforce supplier. Good communication is the key to a successful completion of a project.

Die Selection – Technical Data

Types of Embossing and Dies

Blind Emboss: Blind Emboss is Embossing done on a substrate with no form of printing or marking in the Embossed area. The colour of the Embossed image is the same as the colour of the substrate. It is also known as Self-Emboss or same colour Embossing (2D, 2½D or 3D Die required).

Registered Emboss: An Embossed image that exactly registers to a printed or foil stamped image. The printed image area is Embossed to give it a raised look (2D, 2½D or 3D Die required).

Single-Level Emboss: Embossing where the image area is raised to just one flat level (2D, 2½D required).

Multi-Level Emboss: Embossing where the image area is raised to multiple levels having different depths and angles. This gives the Embossed image texture and added relief (3D Die required).

Sculptured Emboss: An Embossing style originally referred to a hand chiselled Engraving process. Now it is more often than not a CNC Engraved Die with occasional hand finishing. The process starts with a photograph or a drawing with various levels of depth to make the image appear realistic and multi-dimensional (3D Die required).

Printed Emboss: A style where the substrate is first printed and then Embossed in registration on the printed image. Depending on requirements a bevel can be included which can be either within the print image or outside (2D, 2½D or 3D Die required).

Tint Emboss: This style involves the Foil Stamping and Embossing of the image using pearl or pastel foil. Tint Embossing is the same as other Embossing but the use of pearl or pastel foil creates a unique and classy look. It is strongly recommended to use white stock for tint Embossing because pearl and pastel foils are transparent (2D, 2½D or 3D Die required).

Combo Emboss: This refers to an Embossed image that is also foil stamped (2D, 2½D or 3D Die required).

Glazing: Glazing is a technique where a mirror polished Embossing Die is used to Blind Emboss, using heat and pressure, to create unique effects particularly on dark coloured plain and textured substrates. When Embossing, by substantially increasing the heat and pressure, you are able to add a shine (burnished effect) to the surface of a matte substrate. When Embossing at very high temperatures, using light coloured paper or card, a scorched effect colour change will occur on the substrate. If done properly, this will create great contrasting effects and designs (2D, 2½D or 3D Die required).

Gloss Emboss: This is a technique of combining a clear foil (similar to varnish, but deeper) with Blind Embossing, producing a high-gloss Embossed image.

Debossing: The surface is depressed instead of raised as in Embossing (2D, 2½D or 3D Die required).

Single Level Embossing: Raises an image above the stock level, on a single level (2D / 2½D Die required).

Single Level Debossing: Presses an image down into the substrate, on a single level (2D / 2½D Die required).

Multi-Level / Sculptured Embossing Dies: A realistic impression and illusion of a three dimensional image, for example a face (3D Die required).

Textured Embossing Dies: Textured Embossing produces a tactile quality to Embossing or Foil Stamping. Embossing and De-bossing techniques are great ways to add dimension and elegance to logos, images, headlines and other text. They can also be used to create texture and other realistic effects that mirror the printed design of a project. An extensive range of textured Emboss effects can be created to enhance the background or be combined with other Emboss images. Common textures are pebble or wood grain effect, but the list of effects that can be created are endless.

Duplicates: Phenolic or plastic duplicates taken from original Engraved Dies for use in place of, or alongside the original Engraving. Duplicates are most commonly used when one image appears several times on the same master sheet.

Combination Foil/Embossing

Engraving in metal allows you to create near photo quality multilevel or sculptured images.

CAD design software and CNC Engraving machines allow the designers to create elaborate designs accurately, consistently and quickly and at a relatively low cost. Advances in communications, electronics, software and automation have opened up all types of technology for the printing and allied industries. The manufacturing time and the cost of creating sculptured Embossing or combination Die is a fraction of what it once was. Not many years ago Engravers were using a hammer and chisel to carve out intricate images for Embossing, making Engraving a very labour intensive, time consuming and expensive process. Though hand engraving still takes place, it is limited to specialist work or where programming on CAD-CAM software would take too long.

Examples of printed products including Embossing can be seen everywhere from Greeting Cards, Book Covers, Business Cards, stationery, Cereal Boxes, Perfume Packaging, Presentation Folders and much more all use sculptured Embossing and combination Dies. Just about everything in today’s print media market is open to sculptured Embossing and Foil Stamping.

The creation process of making a sculptured Embossing/combination Die begins with the customer and designer discussing the project. Deciding what type of Foil Stamping and or Embossing is required, what type of Die and Counterforce is required, shapes and textures within the designs, what type and thickness of substrate will be used. The overall look and feel, the finish, the areas where foil is to be printed, the print and or Embossing run and so forth. All these and more will affect choices made in the CAD-CAM design, Die material, Engraving depth, whether hand finishing is required and so on. 

Combination Work

Combination foiling and Embossing, or foil Embossing integrates Foil Stamping and Embossing into one press pass through the use of a combination Die, which is usually a Brass-sculptured Embossing Die.

Print – Emboss Substrates

Selecting substrates for Embossing:

The texture of paper and board are important when Embossing. Sometimes textured paper is Embossed to smooth out the paper in the image area and sometimes, smooth paper is used for Embossing and adding texture to create a striking finish. Whichever way you do it, Embossing can produce some amazing effects especially when combined with Hot Foil printing.

When Embossing, paper and or card is stretched in the image area. Heavy, long fibered materials are structurally stronger and therefore, using these types of paper and or card stock reduces the possibility of damage to the substrate when Embossing. In contrast, lightweight, heavily coated or varnished papers and or boards including recycled materials, are not suitable, as they have a tendency to crack easily. As a rule of thumb the more processed a paper is, the shorter its fibres, so the weaker it becomes and therefore cannot withstand the pressures of Embossing.

When Embossing, the depth and degree of bevel achievable is determined by the substrate. A thicker substrate can produce more dramatic Embossing effects because the impression can push deeper into the substrate and varying levels of relief become possible.

ü Suitable

~ Maybe Suitable

X Not suitable

– Not Applicable

Paper Guide and its suitability for Foil Stamping

Labelling and packaging design and production companies and their customers recognise the powerful visual impact created when incorporating Hot Foiling and Embossing within their design. Many companies including some of the world leading consumer brands adeptly embellish their print with Hot Foil printing and or Embossing to great effect, helping them increase customer confidence and brand loyalty. Hot Foiling using standard or custom holographic foils can also be used to reduce counterfeiting and at the same time enhance the visual appearance of the print.

Dark coloured substrates present its’ own set of problems. The opacity levels of pigments in the different types of foils available and from different manufacturers may vary greatly. The resulting colour of the printed image and the contrast between then on a dark substrate may not be acceptable to the client. This applies to translucent pastel, light colour foils, high gloss pigment foils and so forth.

A simple solution to solving colour compatibility is to create overlays. Use transparent plastic cards or cut sheets of polyester, acetate or other similar products to a suitable size. Produce a metal Die which should include thin lines, solids and text.

An example of a colour check card

Using different colour and types of foil print a few test cards of each colour and mark each card with the foil supplier and foil product number or code. This will make it easier to identify the foil later. Once printed place the transparent colour check cards onto any substrate to check colour compatibility. This method is particularly handy in helping customers choose the best foil colour for the substrate they want to print onto.

Design & Artwork Planning

Preparing Embossing Artwork

To achieve high quality Embossing or Debossing, it is essential that all the stages of production are correct and of the highest quality. Artwork creation is the first stage in the process and it is extremely important to get that right. Not all artwork designs are suitable for Hot Foil printing and or Embossing. Some designs are better suited for plain substrates rather than textured and similarly some designs are better on thin rather than thick substrates. When Embossing thin artwork, the Embossing will not be as deep as you would have, if the design was bold. When combining thin and bold lines in the artwork, the resulting Embossing will produce uneven results. Avoid designs incorporate fine patterns such as halftones as they do not Emboss and or De-boss well.

• Keep the design uncluttered and bold. Avoid too many fine details and tiny crisscross lines.
• When using lettering use sans serif fonts such as Arial and space them so that there is enough space between each letter to allow for the Embossing effect to be properly created.
• Slightly Increase the size of the art, to compensate for the added dimension.
• For multi-level Embossing it is best to use colour codes to indicate the various levels.
• Keep the image area at least 6mm / ¼” away from the edge of an oversized sheet to avoid puckering or wrinkling. If the Embossing is being done on a finished project, keep a 13mm / ½” margin.
• To prevent dissatisfaction and ensure success and overall customer satisfaction, it is critical that the customer, the artwork designer and the Die maker, talk to each other and fully understand the customer’s requirements. The best way to avoid problems is to listen carefully to the customer, make detailed notes, ensure that the customer’s specifications are correct and share information openly with each other.

Artwork design for Embossing and Foil Stamping Dies

• When designing artwork for single level Embossing Dies, output your artwork off a high quality imagesetter, 1200 to 2400 DPI laser printer, or a good quality photocopier.

• Attach a velum overlay and write clear and detailed instructions of what is required for your Die manufacturing department or Die maker.

• Whenever possible, all line / rule thickness should be 2 pt. or more, this is because of the inherent bevel, smaller lines are more difficult to Emboss cleanly.

• For optimum foil printing quality, use line art and avoid type smaller than 8 pt. and copy with tight intricate detail may plug (infill).

• Mark the vellum overlay attached to the artwork specifying if a bevel or round edge is required and the type of substrate to be Embossed.

• Embossing thick card normally produces excellent results, although Embossing on thinner materials will produce a better quality and more detailed Embossing.

• When Hot Foil printing and or Embossing it is strongly advised to keep away from crease / fold lines.

• To accommodate the bevel (the relief image’s “face to base” shoulder angle) on the Embossing Die, it is recommended that the artwork should be slightly larger and heavier than the artwork required for offset printing.

• Greater the Embossing depth required, the more kerning (letter space) must be incorporated into the Die artwork design. This is because the larger bevel will take up more space around each element of the image. Extremely small and intricate designs should be avoided, but by working closely with your Die making department or your Die maker, you should be able to reproduce fine detail of reasonably good quality.

• When designing artwork for multilevel (combo) Dies, output your artwork off a high quality imagesetter, 1200 to 2400 DPI laser printer, or a good quality photocopier. For complex multilevel jobs, it is recommended that you colour code the various levels with permanent ink markers (felt tip pens).

• Create a depth and bevel chart and with a series of engraver’s symbols you can mark the overlay that will indicate to the Die making department or the Die maker the desired effects required.