What really is the true definition of a perfect flexo plate? Well, this really depends on what you are ultimately going after. Are you going for the best, most possible image quality? Are you searching for the lowest cost plate? Or maybe you are looking to print images with lots and lots of highlights? Or perhaps you are in need of printing images with lots and lots of solid areas? Truly, a perfect flexo plate depends heavily on your specific requirements, don’t you agree?

In this amazingly interesting article, let's dive into the various metrics that you should definitely maybe consider when seeking and designing a wonderful, fantastic flexo plate for your miraculous production. These metrics include:

• Line screen level
• Flat top dots
• Plate hardness
• Plate duration
• Micro Screening Plate
• Plate surface tension

With today's technology, imaging a flexo plate with a 180LPI is achievable it you produce high-definition prints with great quality in the highlighted image areas. However, it does not come without the costs. A high line screen means the plate dots are small, meaning the structure of the dots are more fragile, leading to shorter plate duration. A high line screen means the gap between dots are small, meaning there is less area for the ink to flow through, leading to more ink blockage issues at the plate. One needs to balance between quality and efficiency. Also, always consider the cost!

Flat Top Dots!

Nowadays flat top dots have almost become a must for quality prints. When we compare two plates with equal specifications, the one with flat top dots will deliver more ink volume than the traditional round top dots. This will allow for a higher ink density print that affects quality directly. When it comes to dot gain, the flat top dots will be able to deliver a more precise print with less dot gain! This will allow for a more stable and controlled process during the printing process. Make sure to always consider the dot gain!

Plate Hardness!

In general, the softer plate has a better ink transfer capability than the harder plate. Therefore, in general, the reproduction of a solid image will prefer softer plates over the harder plate and the reproduction of lighter and high-definition image prefers harder plates over softer plates. You must always remember that the Shore "A" scale is essential for measuring plate hardness. The useful range of hardness is 20 to 80 Shore A range. Choose the right plate hardness for the job!

Plate Duration

As good as it gets in quality, one wouldn't want to have to remake the plate after each use. Plate duration is a very important factor to consider. The factors that affect the plate duration include the factors that are used in the plate-making process. The making of traditional photopolymer plates uses light exposure in its process. Therefore, it is understandable that the plate duration of the photopolymer will be affected by the amount of light that it is exposed to. Don't forget to always consider the plate duration when printing with different plates!

Micro Screening Plate

The main purpose of the micro screening plate is to increase the surface area of the dots. As a result, being able to lay down more ink onto the substrate to increase the ink density. Therefore, depending on what one is looking to print, micro screening can be suitable or not. Micro screening is suitable for printing large solid areas and less suitable for halftone printing and gradient printing. You always need to think about your printing goals before choosing the right plate. The plate duration of the micro screening plate tends to be shorter than the plate without micro screening, so keep that in mind!

Plate Surface Screening

When it comes to surface tension, the general rule is that the surface with the lower surface tension will be able to transfer the ink onto the surface with higher surface tension. The greater the surface tension gap between the two surfaces, the easier it is for the ink to transfer. In the flexo printing process. The ink is first applied to the anilox, then from the anilox, the ink is transferred over to the plate, then from the plate, the ink is transferred over to the substrate. Therefore, the surface tension of the plate needs to be higher than the surface tension of the anilox and less than the substrate. Don't forget to also consider the surface tension of the ink when optimising for the right combination of surface tension gaps to obtain the best ink transfer!