Product Spotlight

Embossed Foam Backed Metal Plate

Step One - Screen Printing

The silk-screen process begins with a film positive output from a digital file. The positive is converted into a woven fabric ("silk") photoscreen which is mounted on a large hinged frame below which the material to be screened has been positioned. The frame is lowered onto the stock, and the silk-screen paint, or ink, is squeegeed through the open image areas of the photoscreen. The product is then placed on special racks to dry.

Step Two - Embossing

Embossing is the process of creating a three-dimensional image or design in ductile materials. This is achieved by using a metal die (female) and a counter die (male) that fit together and mold the image into the substrate. Generally the letters or other designs are embossed to make the product appear to come out at its viewers.

Step Three - Foam Backing

Foam backing is a pressure sensitive adhesive material that is applied to the reverse side of the product through a process known as lamination. In this process the adhesive foam material, as well as the substrate to be laminated, is sent through two rubber rollers sandwiched together, compressing the pieces to form an extremely strong bond. This foam material is generally used when the products will be applied to a textured surface. Also because of the approximately 1/8" thickness of the foam adhesive, it gives the item a more three dimensional look.

Step Four - Die Cutting

Steel rule die cutting is a common process used to cut a range of sheet materials such as vinyl, polycarbonate, and aluminum. The die is constructed out of a high-grade and high-density plywood. Some special dies may require aluminum or steel substrates. The die-maker tool to cut precisely positioned slits into the substrate. The steel rule itself is essentially an elongated razor blade made out of hardened steel. The die-maker cuts and bends the steel rule and positions it into the slits in the substrate. The final step in creating the die involves the addition of ejection rubber. Rubber pads are adhered to the substrate to help eject the material after it is cut. Without the inclusion of ejection rubber, the material may tend to get stuck amongst the steel rules.