Embossing, the process of raising logos or graphic images, is a great way to augment the visual impact of any component. The tactile feel achieved as a result of the raised design reinforces the aesthetic appeal of a product. Embossing is one of the most versatile metal decoration techniques employed by a wide array of industries.
While there are different ways to emboss a component, how do you ensure the utmost precision while embossing decorated parts? How can the varying tolerances of the decoration process accurately align to a mechanical embossing operation? The answer to all these questions lies in our video below that clearly demonstrates the advantages of adding an optical registration system to the embossing process.
To illustrate the registration challenge imposed by any decoration process on embossing, let’s delve deeper into the HySecurity nameplate seen in the video. During the screen printing process, when a squeegee travels across the metal sheet, the deposition tolerance between the images can vary as much as 0.005” per inch. As such, an image from the leading to the trailing edge of a 24” sheet can vary around 0.12” (0.005” x 24”). Conversely, the mechanical action of the embossing die does not exhibit this variation. So, when an operator feeds the metal sheet to the embossing machine, the tool cannot align accurately with the varying deposited images, sometimes creating an off-registered embossed part.
We can overcome this alignment challenge by adding an optical registration system to the embossing process and depositing a corresponding registration mark next to each design. In doing so, when the nameplate is being screen-printed, a registration mark is put down at the same time that correlates to the center of each artwork. At the embossing stage, the press uses an optical eye to locate the mark and make necessary adjustments to gain alignment between the printed graphic and the tool pitch, resulting in perfect embossing. Since the press automatically calibrates the location of every individual artwork and advances the sheet through the press, the process is ideal for parts that demand extremely tight registration. Resulting in extreme precision and accuracy, optical registration embossing provides a high degree of efficiency and consistency. The press overcomes tolerance variation that the actuator-fed emboss press falls short of.
The press can emboss a range of metals and alloys including stainless steel and aluminum. While the thickness of the material processed is directly related to the press tonnage of the machine, the embossing height depends on various factors such as the thickness, temper, and alloy of the metal. Since certain alloys have greater elongation characteristics, they can be embossed to a greater height as compared to the others. The press can emboss, deboss (recessed images), or perform both the processes simultaneously. It is well suited to emboss parts that are either screen, pad, or litho printed. Depending on the design intent, embossed parts can undergo secondary processes like forming, blanking, and die-cutting at a later stage. To see how the Vforce nameplate, featured in the video, went through diamond carving after it was embossed, watch our video here.
Over the last few decades, GMN has worked with several leading companies including Ford, Dell, Estée Lauder, and DW drums, to create clean and crisp embossed parts. To watch the embossing process, click on the video below.