Professional Documents
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GS3200wide Format Digital Imaging Printer On Any Surface.
GS3200wide Format Digital Imaging Printer On Any Surface.
Contents
THE BASICS 1
PURCHASING: DISTRIBUTORS & DEALERS 2
FEATURES OF THE PRINTER: Vacuum 3
STRUCTURE OF THE PRINTER: Media Transport Mechanism 4
STRUCTURE OF THE PRINTER (if a combo style): Transport Belt 5
LINING UP FLAT MATERIAL (to help it feed straight) 6
ROLL-FED 14
STRUCTURE: Miscellaneous 18
UPGRADES, Future Improvements? 18
Miscellaneous 19
OPERATING THE PRINTER 19
CONSTRUCTION (BUILD QUALITY) 21
AESTHETICS 22
SET-UP OF THE PRINTER: PRACTICAL CONSIDERATIONS 22
INSTALLATION OF THE PRINTER 24
INSTALLATION OF THE PRINTER: INSTRUCTIONS & MANUALS 25
Please Note TRAINING 25
TECH SUPPORT & WARRANTY 26
This report has not been licensed to any printer CLEANING & MAINTENANCE NEEDS 26
manufacturer, distributor, dealer, sales rep, RIP MAINTENANCE 29
company, media or ink company to distribute. SAFETY & HEALTH CONCERNS 29
PRINTHEAD TECHNOLOGY 33
So if you obtained this from any company, you
PRINTHEAD DPI & Features 34
have a pirated copy. Bi-DIRECTIONAL VS Uni-DIRECTIONAL PRINTING 36
PRINTHEAD Positioning 36
Also, since this report is frequently updated, if you PRINTHEAD: Associated Features 37
got your version from somewhere else, it may be an PRINTHEAD Life Expectancy 37
obsolete edition. FLAAR reports are being updated PRINTHEAD CARRIAGE and GANTRY 38
all year long, and our comment on that product may SUBSTRATES 38
LOADING MEDIA 39
have been revised positively or negatively as we
SUBSTRATES, Materials, Applications, and Issues 40
learned more about the product from end users.
SUBSTRATES: Cleaning, Priming, Preparation 41
SUBSTRATES: General Concerns 42
To obtain a legitimate copy, which you know is the WHAT IS THE INTENDED MARKET FOR THIS PRINTER? 42
complete report with nothing erased or changed, and APPLICATIONS 43
hence a report with all the original description of pros INK 43
and cons, please obtain your original and full report INK: White & Varnish 44
straight from www.large-format-printers.org. INK Cost 45
INK: Supply System, Tubing, Filters, etc 46
Your only assurance that you have a complete and INK Color Gamut 46
THE UV CURING LAMPS 46
authentic evaluation which describes all aspects of
UV LAMPS: Cooling 48
the product under consideration, benefits as well as
RIP SOFTWARE & Printer Software 50
deficiencies, is to obtain these reports directly from
COLOR MANAGEMENT FEATURES 50
FLAAR, via www.wide-format-printers.NET. GENERAL CONSIDERATIONS 50
COMPARISONS WITH OTHER PRINTERS 50
Copyright 2010 SUMMARY: Image Quality Issues: Banding 51
SUMMARY: Image Quality Issues: General 53
Conclusions 54
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2. If there are two or three (or more) widths of this printer, what differences exist other than the width?
There is only one width: 321.3 cm (126.5”), but the GS family has a smaller version, the GS2000 which accepts media up to 203.2
cm (80”).
This evaluation is based on notes taken at EFI demo room in Meredith, NH., plus notes from several trade shows around the world (ISA, in
Orlando, FESPA in Munich, APPPEXPO in Shanghai, etc).
7. What accessories are extra charge? Are these same or similar accessories included with other printers at no extra
cost?
The MediaMaster is not included in the purchase price. There is also an optional heavy-duty unwinder.
The MediaMaser includes front and rear structures. The price is US$125,000.
The MediaMaster is the automatic board feeder discussed in detail further on. It was first exhibited at ISA 2010.
8. Does a complete set of full-sized ink cartridges come with the new printer, or merely a “starter set” that is not as full
as a regular set?
You get a starter set; one box of each color.
9. Does the manufacturer have distributors in all continents? Or only a few dealers and missing key world areas?
EFI has distributors in most major cities in the world.
10. Are dealers national (most companies) or regional (Roland allows a dealer to operate only within a limited regional
area)? Does a buyer have any choice in dealers?
The countries that are not directly covered by a distributor, are covered by the distributor in a neighboring or close country. For ex-
ample, the EFI VUTEk distributor in Scandinavia region also covers the Eastern European countries.
15. Are the vacuum areas (size and position) user definable?
Yes, there are no fixed sections.
16. Can you turn one or the other section(s) off and on?
Yes, you can have only the area covered by your material, and the rest turned off.
18. Is the vacuum too weak for some materials? Does this mean you have to waste your time and tape materials down
to the top of the flatbed table?
The vacuum will not hold a board if it is warped. This is not a failure but a practical reality. This is a technical aspect you are warned
about.
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EFI VUTEK GS3200 4
For Rigid and Flexible Materials
19. Is there a moving transport belt (combo style) or a stationary platen (hybrid style)?
This is a combo printer. In other words, rigid media is moved forward with a conveyor belt. So this printer can handle both rigid and
roll-fed media.
From the Agfa :Anapurna M printers (158 cm print width) up to the Durst Rho 1000 (250 cm print width) you notice that most combo
printers are in this range of print width. If you take on account its 321 cm print width, the EFI VUTEk GS3200 is the widest UV combo
printer in the market.
The feeding mechanism of the EFI VUTEk GS3200 is based on a moving transport belt. There is no standard in the industry and although some
people call these type of printers “hybrid”, FLAAR classifies the printers with moving conveyor belts as “combo”.
20. Are there edge guards at each side (end) of the platen? At left, or at right, or both?
No. There are no edge guards.
21. Was this printer made originally as a UV-curable ink printer, or is it retrofitted with UV-curing? If retrofitted, what
was the original brand or model?
This model was built from the ground up to be a UV-curable printer but EFI VUTEk has experience as a manufacturer of several tech-
nologies, including solvent, UV, and textile printers.
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Belts that are solid may track well but may be especially difficult to replace.
23. What is the kind of material out of which the transport belt is made?
The belt is made out of nylon.
24. Can the belt move forwards and backwards, or only forwards?
Yes, you can enter a value of transport belt movement, either forward or backward.
I only began to ask this question when I learned that the transport belt of the Sun Neo LED Evolution could go either forwards or back-
wards. The reason on that printer is because the white ink heads are set behind the others. So if you want to do a pre flood coat you
print in one sequence; if you need to do a post white ink layer, you move the material in the opposite direction.
I would thus consider the ability of the GS 3200 to move backwards as well as forwards a useful feature, and one possibly not found on
all competing brands.
25. How many rollers control the belt: is the path of the belt horizontal, or triangular?
The front roller has a servo motor at the right. This is the drive roller. The path of the belt is horizontal.
You should expect at least one drive roller and one driven roller, one at the front the other at the back. In between is a rectangular
horizontal vacuum bed, essentially the same kind of bed you get on a dedicated flatbed printer.
The IP&I Revo has three rollers, as does the new Shark from Grapo. The IP&I Cube260uv has four rollers that control the transport belt.
This adjustment and alignment control system on the IP&I Cube UV printers is the most sophisticated I have yet noticed.
26. How well does this belt hold up to heavy use? Does it skew?
There haven’t been any reports of a belt skewing so far. EFI VUTEk has plenty of experience building printers with this type of media
feeding mechanism.
You can check this yourself to some degree by looking at the transport belt from either side. Have the lighting shine on the belt so that
you can see the horizontal sections. What you want to see is whether the woven aspect of the belt remains straight, or whether it has
shifted from stress and strain.
Several other UV printers have an infamous record of belts that may be so unstable that they “wander.”
But with even the combo belts that are considered acceptable, some materials will skew: depends on belt usage, wear-and-tear, on
material weight and surface characteristics, etc.
The MediaMaster, is a very solid structure located at the back (in this photo) and a similar structure at the front. One of the advantages of an auto-
matic feeding system is that your production times are shortened and less personnel is needed.
Take-up table. The similarity between the rear and front tables can sometimes make it difficult to distinguish which is the front and which is the
back of the printer.
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Media is stacked at the back. Metal stops keep the pile from moving.
Similar pieces make it possible to stack the boards perfectly aligned at the front.
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The tables of the MediaMaster are based on conveyor strings moved by the rotating rollers. The rear table receives the boards and transports
them into the printing area.
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A camera (1) reads the position of each incoming board comparing the edge of the board against a registration code (2) printed in the edge of
the rear table.
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The MediaMaster comes with a mid-sized computer monitor (around 17” wide). The registration code can be seen through the software.
The operations are performed in part through physical buttons located in the main control area, and in part through the computer.
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After being printed on, media is received by the take-up table which drives boards under the front suction vents.
Then, the vents lift the boards and place them on front stacks. There is little operator intervention with this mechanism, which means one operator
could be running another printer while the VUTEk GS3200 is printing.
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Each of the vents has a suction regulator connected to a small pump. The whole system is based on DC (direct current) motors, which
are often used in robotics.
As explained earlier, the MediaMaster is an option available for US$125,000. Currently this mechanism is only available for the EFI VUTEk
GS3200.
In the near future EFI will release a second version of the MediaMaster, which will be able to load media directly from the pallet. There
will be a narrower distance from board to board.
29. Is there a registration gate that is lowered across the back printing area?
Yes, there is a media fence at the back to align rigid boards.
Most printshops report that most rigid media is crudely cut and rarely are the edges really at 90° to each other. So you don’t really want
to align a corner, you want to align one side (on one end).
30. Does the drop-down gate have moveable features to assist in registering materials?
Yes, the media fence has a number of media alignment blocks that can be slid along the media fence and placed wherever needed.
31. Can you be feeding or aligning new material at one side of the printer while the previous job is still printing out the
other side?
Yes, it is possible. Feeding new material will be more efficient when the automatic feeding mechanism goes out of beta stage.
32. Is two-sided printing realistic? Is there a mechanism for registering the position of the image on the second side?
Yes it is possible. Since the earlier QS models, you can print one side, flip the substrate over and instead of aligning it to the left, you align
it to the right edge. Take on account that the best way to print both sides on a combo with perfect registration is to have registration
pins like does the IP&I 1606, the HP Scitex FB950.
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2
There is a media fence (1) at the back that is lowered to align boards. There is a metric strip (2) for a more accurate alignment of boards. The
media fence has a number of metal blocks (3) that can be slid wherever needed.
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ROLL-FED
The hold down media roller (1) helps the system to keep media flat.
A saddle is formed of two rolls with a slight space between them. You rest
your roll of substrate on the saddle created by the two adjacent rolls. You
don’t need to run a spindle through the roll. You don’t need to fumble loading
the end of the spindle into two holders (one at each end). Loading a saddle
is quicker as a result. But a saddle is primarily used on heavy-duty industrial
printers 3.2 meters or wider where the weight of a roll may cause a spindle to
sag. Plus, it’s a headache to thread a spindle through a 5-meter long core.
Air core spindles tend to be used only on grand-format printers costing over
a quarter of a million dollars.
36. After the feed roller (or spindle) is there a set of two fixed bars,
Roll-fed media goes from the spindle straight to the con- one above either other (a tension set)?
veyor belt. There is no intermediate roller that creates The heavy-duty unwinder has a dancer bar. Otherwise in the standard model
tension, because tension is created by the spindle and the media goes directly from the transport belt to the spindle.
vacuum system.
37. If this is a dedicated flatbed or a combo design, is the roll-fed mechanism an option, or is it included?
Since the model exhibited at ISA ’10 was meant to print on rigid materials, it did not have the spindle installed. However, the spindle
does come with the printer.
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Feeding and take-up spindles hold the roll media core with an air pressure system.
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Feeding and take-up media rolls have a small control panel at the right end to control tension and direction of rotation.
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With some brands of printers you suspect that they are deliberately designed to waste ink and media since this is how those companies
get their profits. Media is moved too far out before you can cut it, resulting in media being wasted before and after cutting, etc.
The amount of waste also depends on whether you need to attach the leading edge of the media to the take-up spool, or whether you
can simply leave the leading edge up on the platen or up on the conveyor transport belt (as is possible on the Grapo Octopus II and
some other combo printers).
There is less waste on a dedicated flatbed printer because there is no material used in loading or feeding up to the point it is printed
upon.
There is almost no waste of media because the front end of flexible materials can be held down and tensed with the vacuum system.
41. Can you print on more than one roll of substrate simultaneously?
Yes. Depending of the width of your rolls you can print two rolls simultaneously. The MediaMaster feeds up to three boards at a time.
Being able to print on several different rolls of material simultaneously is common on grand format solvent-based printers but almost
unknown (and unavailable) on printers less than 104 inches. The Durst Rho 351R offers an option to allow printing on two different rolls
simultaneously.
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STRUCTURE: Miscellaneous
42. For handling ink that passes through the weave of fabrics or mesh, is there a trough? Or other mechanism to catch
the ink?
No. There is no system to capture ink that passes through materials like fabrics or mesh.
A trough is possible most easily on a printer with a fixed platen. A trough for mesh or fabrics tends to be present only on a printer cost-
ing a quarter of a million dollars or more. There is no easy way to put a trough on a combo style printer. If you need to print on fabric
or mesh with a UV combo printer you need a liner or you need to put an intermediate sheet onto the surface of the conveyor belt (or
clean up the ink that passes through the weave).
44. Is there a “knife guide,” a slot where you can draw your knife down and across the width of the substrate?
Most combo-style printers have no area to put such a knife slot.
45. What features have been added, or changed since the printer first appeared?
The MediaMaster was developed months after the printer’s official launch.
46. What features have been added in the last six months?
In the most recent version, the printhead carriage has been redesigned to eliminate degassers. Degassing ink is now achieved by heat-
ing ink in secondary ink tanks.
EARLIER VERSION
CURRENT VERSION
In the most recent model, degassers for each ink line have been eliminated because gas is eliminated by heating ink in the secondary ink tanks.
Miscellaneous
For example, on the Inca Columbia the flatbed itself moves in and out for every line of print. The 3M (Leggett & Platt) machine is unique
in that it has two options for movement, both the material and the head assembly in X, Y directions.
Most traditional combo style UV printers move rigid materials with the transport belt and move roll-fed materials through a combi-
nation of the transport belt and the roll-feeding and take-up rollers.
48. Can the operator manage print jobs via the Internet with this printer?
Not normally.
Sending jobs via internet is a function that implies not being present in the printer room, which is not recommended.
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49. What is the level of ease of use? Can anyone use this printer or do they have to be trained and certified? What about
daily and periodical routine maintenance?
The printer is easy to use. A person can be trained quickly to have the GS3200 printing. However, full training is necessary to perform
more complex procedures such as working with the RIP, maintenance, etc.
51. Do you get an LCD screen in the printer or other real computer monitor? How big is the screen or monitor?
Yes. You get a real computer with the printer.
53. Can the keyboard be moved or is it fixed into the structure of the printer?
The keyboard is not fixed into the ledge.
54. Is there a drawer under where the computer keyboard is (a drawer for storing odds and ends)?
Yes, there is a hollow area in the ledge to put tools. Besides, at the right of the monitor there is a cavity for mugs or tools.
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60. How many operators or operator assistants does this printer require?
One operator is enough, especially with the MediaMaster. After initial setup, there is not much the operator needs to do.
64. How would you describe the overall workmanship of visible parts? Clean (Swiss made), or flimsy and uneven
(several Chinese-made printers)?
The GS3200 is well made. The workmanship is clean. Even the ink containers area is clean. I have evaluated other UV printers whose ink
containers are all dripped and dirty.
65. Does the printer wobble back and forth when printing?
No. The machine is solid enough and there is no vibration.
AESTHETICS
67. Can you easily distinguish which is the “front” and which is the “back’?
Front and rear faces are very similar. At first sight you only tell which is the front by the position of the monitor.
I call the front the area where the LCD and operator panel(s) are situated. This usually means that the other side is where you feed the
material in. I call that the back. But many printer companies call the feeding area the front. It makes no difference as long as you define
what you mean in advance.
Some UV-curable printers have a moveable control computer that can be situated at one end, or at the feeding area (whichever loca-
tion the operator prefers). But the standard arrangement is that the LCD and keyboard are on the output side. I call this the front.
Front of the printer (left) and back of the printer (right) are indeed very similar. This similarity increases with the MediaMaster.
68. What is the delivery time, between the time I order the printer and it is delivered?
Delivery time depends on the region and the dealer, but the GS printers have an average delivery time of 8 to 12 weeks.
69. What are the electrical requirements of this printer? This means, will the building have to be rewired.
3 phase, 60 amps (4 wire Delta or 5 wire Y), 200-240 VAC, 50/60 Hz.
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A power cable is not included with the printer because each city has differences in the nature of the power service. Therefore, a cable
should be supplied by the customer. To ensure that the printer’s dedicated power source meets the requirements for this printer, it is
strongly recommended that a local licensed electrician handles electrical installation in your facility.
All UV printers need room ventilation, for everything from ozone to misting ink to general odor. Increasingly ozone production is sur-
prised; this has led some companies to claim that “no ventilation is needed.” Such a claim is dangerous, especially in a country like the
US where litigation is so common. Has Agfa never heard of misted ink? Ink mist is what the printer operator could potentially breathe if
the ink is misting (many printers mist, most notoriously the Infiniti 1600 models; the ColorSpan 72uvX also mists a great deal).
71. Are there any special temperature or humidity requirements or preferences of this printing system?
Temperature needs to be in a range 68°F to 85°F (20°C to 30°C). Humidity range is 30% to 80% (non-condensing)
72. What is the connectivity? Network, SCSI, FireWire, USB or USB 2, or other?
Sending files can be done via Network, USB, and CD or DVD.
73. What air pressure is required to be provided to the printer? Is this for a vacuum table, or other purposes (such as
ventilation)?
95 to 150 psi (6.7 kgf/cm2 to 10.2 kgf/cm2) Dry air only.
74. Realistically, how much surrounding and support space will the equipment need in addition to the machine’s own
footprint.
The following diagram explains the space requirements for the GS3200:
Note: These are the minimum dimensions given in the Printer Specifications
document, based on using 4’ x 8’ (1.2 m x 2.4 m) boards. If you print on larger
boards, you will need more space at all sides.
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If you rent a fork-lift truck, keep in mind that the weight of the printer with the crate
is around 4.25 Tons.
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TRAINING
87. Is training included in the purchase price? If so, what kind of training is offered?
Yes, training is included for two people.
Yes, training is essential for any UV printer, whether an entry-level machine or high-end. Lack of training, incomplete training, and lack/
or of experience are a factor in about a third of the problems that people have with UV printers. Another third is often inadequate clean-
ing and maintenance of the ink and printhead system. The other third cause of problems would naturally be weak parts (that wear out
before they should), wear-and-tear (happens even to the strongest parts made in Switzerland), and features that need improvement,
etc).
90. Between the day the printer arrives, how soon is it realistic to achieve full productivity?
No more than one week. The average time is 5 days.
If a printer is mature (and out of beta stage) you can achieve full productivity within a week or month. But many owners have told me
quite frankly, that it took them several months to achieve full productivity (especially owners of the Luscher JetPrint). The longest time
before a printer is really productive is when a printer is still in beta stage when you buy it. It takes a while for the firmware and hardware
to be improved and updated.
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After speaking with many different printshop owners, what I am learning is that if the printer is cheap and junky you will have constant
down time due to the printer breaking down (reports from owners of Infiniti UV printer). If the printer is expensive and complex, it takes
longer to understand everything and achieve full productivity. And when an expensive and complex printer does break down, it takes
longer to repair.
The normal original warranty period is one year but Gerber has had a special offer of “second year free if you buy before such-and-such
a date.
Heads are cleaned with suction blocks (1). There is one block per printhead.
In this sequence you can see that the vacuum purge tray (2) goes up until suction blocks are in contact with printheads. The vacuum purge tray
moves up and also backwards and forwards.
95. To what degree is head cleaning automatic (once you press a button), and to what degree is it manual?
The suction is automatic in the sense that you control it via software.
96. How many levels (strengths) of printhead cleaning (purging and/or sucking) can be accomplished via the firmware
(software)?
Rather than levels, cleaning is measured by time. So it is the same strength, but applied during different periods of time.
97. How often should you purge? Does the User’s Manual honestly indicate how often you should purge?
As needed. The frequency depends on the usage of the printer and when clogged nozzles are detected.
MAINTENANCE
106. What part(s) of this printer need the most attention to avoid breakdown?
Printheads are the most delicate part of the printer.
107. What is the most delicate, or complex, or time-consuming cleaning or maintenance chore?
The most complex task is cleaning the quartz lenses. It used to be more complex on the QS series.
Printhead nozzle plates are fragile. Some manufacturers say never to wipe the actual nozzle plate by touching it. Other manufacturers
requite that you physically wipe the nozzle plate with a swab. A few manufacturers are unsure and change their recommendations. But
no matter that model printer or what model printhead; I would list printhead cleaning as delicate.
GCC’s StellarJet 250 UV manuals have among the best treatment of safety aspects; in other words, they tell you point blank some of the
reality of UV ink and UV lamps. If the warnings do not make you cringe, they are not realistic.
109. How many emergency stop buttons are there? Where are they located?
Four. There is one near each end of the transport belt.
There is one emergency stop button at each corner of the conveyor belt.
The printer will not work if any of the hoods or cabinet doors are opened. If the printer is running and any of these doors are opened, the printer
will cease to work.
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113. Does the hood close down completely to seal the system, or are there a few inches open at the bottom?
Being a UV printer for rigid and roll-fed substrates, the hood has a gap to let boards come off at the front. The printer handles rigid
boards with a thickness up to 5.08cm.
The hood on any hybrid or combo system must allow space for boards to pass through, so it’s hood can never close down tightly onto
the platen area. The design must allow space; this space should be closed off with a skirt. Some printers use flaps or rubber like material;
other printers use skirts of brush-like material.
Most large dedicated flatbed printers have no hood at all (Oce Arizona 250 is the worst offender). Some gantry structures are enclosed
(Teckwin TeckStorm, for example).
114. What keeps UV lamp light from leaving from the space between the bottom of the hood and the platen or trans-
port belt?
The hood has a skirt.
115. What kind of “skirt” exists along the bottom of the hood to prevent light leakage?
The skirt is formed by non-translucent plastic flaps. Each of these units has a small roller at the end so as to not impede the movement
of the board as it comes off the print area.
Unlike other brands of printers, the flaps of the GS3200 are black and non-translucent. Another brand of UV-cured printer uses white translucent
flaps, which fail to shield UV light properly.
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117. What system of ventilation or exhaust system is built into the printer? Or if not required, what would common
sense dictate? Is it adequate to clear the work area of gasses and fumes?
There are two fans on top. These are mainly to get rid of heat mostly.
A ventilation system does not come with the printer. However, EFI does require a ventilation system installed to extract ozone, ink mist,
solvent fumes, and heat from the enclosed area.
The hoses of the ventilation system are attached to the openings of the fans located on top of the printer.
118. What is the noise level, primarily of the fans for the vacuum?
The printer is pretty quiet. The only perceptible sound is the hum of the vacuum.
Normally the vacuum pump is the nosiest part of any UV-curable flatbed or combo-style printer. Roll-to-roll UV printers do not need as
much vacuum table area so are not as noisy in this respect.
119. What moving parts might hit a person if they are standing near the printer?
There is practically no moving part that might hit a person because, as explained earlier the hoods, door cabinets and red caps are
interlocked. The printer will not start any movement if any hood or door is opened.
In addition, the ends of the drive roller (the roller that generates the movement of the transport belt) are covered. There is no rotating
part left uncovered.
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120. Are any other safety or health issues involved? Does the operator need to be concerned with any other safety
precautions?
Safety was an important aspect in the design stage. Changing ink containers does not involve physical contact with the ink because of
the design of the containers. There are no light leaks from UV lamps because the hood has only small windows which are tinted.
121. Is the Operator Manual so poorly translated that you might make a mistake; a mistake that could be damaging to
your health, or otherwise dangerous for your printshop?
Manuals are written in English by people whose mother tongue is English. However literature does get translated to different lan-
guages. In my desk I have a brochure of the EFI VUTEk GS3200 in German, which I got at FESPA Munich 2010.
An engineer from a European printer manufacturer explained that in the European Union, manuals take longer to be released because
manufacturers are required by law to publish manuals in several languages.
Should a trainee need assistance regarding language at EFI VUTEk, a translator is brought in for training.
It is rare that the MSDS of the ink is easy to obtain. If the MSDS is an auto-download from the company website, this is how it should
be. But most companies do not wish the end user to know which brand of ink is being used, so hiding the MSDS is not necessarily an
attempt to hide the dangers, but may be to hide the source of the ink.
PRINTHEAD TECHNOLOGY
The VUTEk printers are one of the few UV printers using Seiko heads. Most UV printers use either Spectra (high-end price range), Konica
Minolta (mid-range printers) or XAAR (mainly entry level printers) Toshiba Tec and Ricoh are other less common brands.
It is reported that one downside of Seiko heads circa several years ago is that they must spit (which waste expensive ink). It would
be useful to undertake a site-visit case study to learn whether the spitting is still necessary, or not. If not (but if we learn this from the
printer operator on-site) we would update our comments in this section.
124. Is the printhead identified in the spec sheet brochure by brand or also by model, or not at all?
Printhead specifications are not commonly published. However, it is open knowledge that this model uses Seiko printheads.
125. Is only the printhead used by itself, or is an entire electronic assembly also from the printhead manufacturer?
The electronic assembly related to printheads is designed by EFI VUTEk, but assembled by another company.
126. How many other printers utilize the same printhead? Have they shown any problems?
The only other wide-format inkjet printers I can think of that use Seiko heads are solvent printers. EFI VUTEk printers are perhaps the
only wide-format UV inkjet printers using this brand.
All components used to build the printer are evaluated and compared. Seiko met the specifications of what VUTEk engineers conceived
for this printer.
129. Can a sensor(s) detect clogged nozzles and can software provide backup nozzles to cover that missing area on the
next pass?
There is no sensor that detects blocked nozzles, but a nozzle print test is one of the daily procedures before starting production.
This is one of the reasons why the printer reaches such detailed prints. Most other printers in this price range use Spectra heads that
produce 50 or 80pl. This does not necessarily mean that Seiko is better than Spectra, but in general the smaller the drop size, the better
the print quality.
133. What is the advertised DPI, and is it true dpi or “apparent” dpi? How is dpi presented (with what adjectives)? How
is this dpi calculated?
With the two optional drop sizes there are two corresponding resolutions: 600 dpi (with 24pl) and 1000 dpi (with 12pl).
134. Does the software use passes or modes to describe quality levels?
Quality levels are described in terms of smoothing, which is the technology used to get rid of print issues such as banding.
FLAAR prefers to use consistent terms that are standardized for all printers so that printshop owners, managers and printer operators
have a fair chance of comparing speed vs quality. By not identifying the actual passes, or by defining pass in an atypical manner, this
results, in effect, in hiding the reality of speed vs quality. Thus we commend those companies that keep to, or return to, the traditional
usage of the term pass(es).
Increasingly most printer companies are not listing the passes that their printers run back and forth. The definition of a pass is not
consistent in any event: FLAAR defines a single pass as the movement of the printer carriage, while jetting ink, from one side to the
other. There is a difference between “single pass” and “one pass” but that needs an entire article (one pass means a page-width row of
non-moving printheads).
Mutoh describes one pass as a complete back-and-forth movement (FLAAR defines that as two passes).
Most printer manufacturers would rather avoid having to state clearly how many actual passes it takes to achieve specific quality levels.
So they create “modes” that are a combination of passes and possibly other features that result in a specific quality level.
The print samples at the demo room used to show the different printing modes specify the level of Smoothing, which is the technology to get rid
of banding.
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136. What is the direction of uni-directional printing? From right to left, or left to right; or both?
Right to left.
PRINTHEAD Positioning
142. How complex is the procedure to align the printheads? When you add a new head, how long does it take to align it?
It is rare to have the User Manual explain the process to align the printheads. The HP spec sheet is helpful in alerting you to the reality of
aligning their X2 MEMS printhead when you need to replace a failed head with a new one: 45 minutes. Even if this honest estimate was
not provided in the spec sheet, it would be ascertainable sooner or later anyway. I commend HP for being ethical in listing this aspect
of maintenance up front, in their spec sheet.
The reason HP does this is because MEMS heads may be prone to spontaneous failure. So you may need to replace one of the hundreds
of heads several times a week (not the same head; but if there are 365 heads, it may be almost one a day; at least that was the failure
rate in 2007; hopefully the failure rate in 2011 is not that high).
Fortunately Seiko heads are not MEMS, so you don’t have to replace one a day !
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143. Can you vary the gap (the distance from the printhead to the media, which is the distance the ink droplets must fly?
Yes, the printhead carriage height can be varied.
146. Or is the entire plate heated and thereby some heat gets to the heads?
Heating the metal plate that holds the nozzle-plate area of the printheads as a group (the base of the printhead carriage so to speak) is
a cheap way that early Chinese printers did their heating. Today GRAPO is one of the few serious UV-curable inkjet printer manufactur-
ers outside China that uses a heated plate to heat their ink (but with 45 manufacturers, there are always surprises). GRAPO has plenty of
experience since they are themselves a signage printshop, so they would not use any system that was not successful.
147. Does any other part of the printer have heat, such as the platen?
No, with the Seiko 508 heads, ink is heated externally.
148. What is the firing frequency (voltage) of the printheads (in KHz)?
18 kHz.
149. Is negative pressure required to maintain the ink (without the ink dripping out the printhead when the machine is
turned off)?
Yes, negative pressure is needed.
150. How often can you expect head strikes? What causes them? Who will replace the printheads and at whose cost?
As mentioned earlier, the Basic Operator’s Guide states clearly that an inadequate lamp setting (e.g. High or Maximum) may cause the
media to deform. This is the major cause of head strikes. The text warns that the warranty does not cover printheads in such case.
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Most ink tubes are black, except for the ones connecting with the secondary ink tanks (1). Notice that the secondary ink tank tubes for white (2)
are a little bit higher than the rest of the tubes for other inks.
152. Where are all the electronics situated? Above the heads, behind the heads? On the back side of the carriage?
The AC power and other electronics are located at the back, in the lower left cabinet.
SUBSTRATES
153. Can this printer handle printer rigid material only, or roll-to-roll only, or both interchangeably?
The GS3200 handles rigid and roll-to-roll substrates.
155. What is the difference between media width and actual print width?
The real print width is actually one centimeter wider than the advertised print width in the model designation.
We have this entry because some printers are called “3.2” because they
Material Claimed by how the accept substrates that are 3.2 wide, but the printer can actually print only
Print width
width model is named 3.1 meters. In such a case the model name is misleading (and incorrect in
a sense). I have even seen some model designations claiming 3.3 when
3.21m 3.21m 3.2m they only hold media 3.2 meters. So there is a bit of misleading advertis-
ing out there.
LOADING MEDIA
The height of media is read by the infeed roller, located at the back.
163. If you have to load a really long roll, are there clamps
or any other system to allow you to secure the first por-
tion so the first portion won’t undo itself while you are
several meters away trying to load the other end?
Since roll-fed media can be held flat with the vacuum, there is
no need of any gripping accessories. Flexible media and rigid media is loaded at the back. With the MediaMaster
boards are also loaded at the back.
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169. Heat concerns: will the heat generated by the UV curing lamps cause adverse effects to some delicate forms of
heat-sensitive media? Which materials might curl, distort or discolor from the heat?
Polyethylene and in general any thin film might be difficult to handle to the lamp’s heat.
Heat sensitive materials for mercury arc UV lamps would include polyethylene, polypropylene, shrink-wrap, very thin and thermal sen-
sitive papers, plastic coated cartons, PVC and aluminum foil (www.dotprint.com/fgen/prod1297.htm).
Oce lists several other common signage materials as sensitive to the heat of UV lamps. For these reasons we have a separate FLAAR
Report on applications and materials.
Heat can build up when the printhead carriage hovers over a small area to print a narrow job. Heat can build up inside the printer as
materials (especially metal) absorb heat and hold it (and then radiate it out for a long time). So heat is not only an issue from the obvious
and immediate heat of the UV lamps. Residual heat can be an issue as well.
You can in effect lower the heat that reaches the material by raising the entire printhead carriage. However this results in noticeably
less quality (because the ink is flying through the air a longer distance while the material is moving away from it). You can also set the
printhead carriage to move further away from the printing area at the end of each pass (in those cases that the media is less than the
maximum and in those cases where these settings are facilitated by the printer design and firmware).
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One way to dissipate heat is to have good ventilation drawing the hot air up and out of the enclosed printer. There are two exhaust
tubes at the top for this purpose. These are not only to suck out the odor and ink mist, but to remove some of the heat too.
170. What about build up of static electricity? What kind of materials cause this? Do some materials generate static
electricity which cause the media to attract ink in areas not supposed to be printed on. How is it manifested?
There are static dissipaters, which are bars placed between the printhead carriage and the UV lamps.
One economical way to get rid of some static is to use a fabric softener
– Downy-for example, which you can get from the supermarket. But be
sure to learn which materials need anti-static treatment. No sense wast-
ing time with those materials which do not have a static issue.
And be aware that the amount of cleaning liquid you put onto a mate-
rial can cause after-effects when that same material is heated by the There is one static dissipater bar at each side of the printhead
UV lamps. carriage.
171. Do you have to brush off or otherwise clean each sheet of incoming material by hand before you print on it?
For flat rigid material generally yes. The need to clean incoming materials is typical of any printer. Some materials have more detritus or
dust or issues than other materials. And some suppliers offer better materials than others.
172. What liquid cleaning material should you use to clean your materials? Which kind of cleaner, and which kind of
materials per cleaner?
Isopropyl alcohol is recommended.
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173. Although this printer “prints on almost all materials,” what is the adhesion rate with most materials? Does the ink
easily scratch off certain materials?
EFI is upfront about the issues with acrylic. Therefore, polycarbonate is suggested as replacement for acrylic.
Realize that all statements must be judged based on how long the ink has been on the material, and the surface nature of the material.
Not all fluted plastic material is the same; and six months later the adhesion could theoretically be different (based on conditions of
display and the nature of the surface of the material).
Adhesion may be difficult on polypropylene and Lexan. Some UV ink does not work well on Coroplast, or prints well but begins to fall
off after several months.
You need to test each material yourself before you promise your client you can do a job that will hold up six months or a year.
The MediaMaster, the automatic rigid board feeder is still in alpha stage, although it has already been exhibited since ISA 2010.
175. What is the market that the manufacturer has designed this printer for?
Although EFI is rather conservative with the applications at trade shows, the GS3200 was designed to be a versatile printer capable
of reaching several markets. In late 2009 FLAAR visited a sign shop in South Korea that was printing applications on glass with the EFI
VUTEk QS3200 (the previous model).
In general, the VUTEk printers are aimed to sign shops looking for industrial production with a high print quality.
EFI VUTEk QS 3200 at RGB Digital Wide Color, a few kilometers away of Seoul, Korea. The owner liked so much his EFI Rastek T660
printer (foreground) that he decided to purchase the larger EFI VUTEk printer.
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APPLICATIONS
Although the range of applications is wide, high-quality POP signage is the specialty
of the GS3200.
INK
180. Is there a special ink for flexible material, and another ink for rigid material? What other inksets are available? Is
there any choice in inks?
It is the same ink.
A number of printer manufacturers advertise two types of ink for their UV printers. Downside of this is that changing from one ink to
another is complicated; you have to clean the whole ink system, install, calibrate, and print. A Manager from another company men-
tioned that the engineering team at her company decided to have only one type of ink because you lose an average of half a liter of ink
every time you change of ink for different applications.
In the past only Hexion and Gandinnovations offered a special heat-formable UV-cured ink. The Mimaki heat-formed samples are
simply a basic generic flexible UV ink that they can stretch a bit; as of summer 2008 Mimaki was not yet using a real dedicated thermo-
formable ink. Mimaki heat-formable ink may come from 3M.
At DRUPA 2008 (if I remember correctly), Durst announced that a heat-formable ink would be available for their Rho printers.
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VUTEk is the division of wide-format inkjet printers. InkWare is the division that
manufactures the inks. Both brands are part of the EFI corporation.
187. To use white ink does that require not using light colors in order to make space for the white ink?
No. You can use light colors at the same time you are using white.
It is claimed that if you have variable droplet heads (and thus can achieve really small ink droplets) that you don’t absolutely need light
Cyan and light Magenta. But on the Oce 250, they claim this and I am skeptical; or maybe it is just the dithering pattern of their Poster-
Shop RIP that causes the noticeable dithering pattern (this RIP is renowned for this issue).
188. What is the sequence of printing the white ink? Can you print all white and then print colors on top?
You can do:
• Colors + White + Colors
• White + Colors
• Colors + White
189. How many ink lines or printheads are dedicated to white ink? One or two?
Two.
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190. What is the shelf life of white ink compared with CMYK colors?
It is the same: one year.
191. Is the white ink tank situated in the same area as the other inks?
No. It is at the back because the white ink has a recirculation system.
INK Cost
What is the cost, in ink, per square unit? Ink comes in 5 liter cardboard containers.
15¢/sq. ft.
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196. How can you see the remaining ink level? ? Do you have to ask to see the ink mode, or is the ink status available at
all times?
You can see the ink levels via software.
197. Can you hot swap the ink (refill with ink while the printer is running)?
Yes, you can just connect the new containers.
198. Where are the printer’s ink containers located? Front, back, or end? Up on top or lower down?
Color ink containers are located at the front. The white is located at the back.
199. Is the color gamut what your clients need for their logos and products? How about red? Does it turn out more or-
ange? Is red bright enough in saturation to satisfy clients? Or are the colors overall a bit dull?
EFI admits that the orange of Home Depot has been difficult to match.
Because the EFI VUTEk GS3200 uses eight inks plus two whites, the color gamut is wide and most colors are accurate.
200. How many different sets of lamps are there? Is there pinning first and then curing later?
The lamps have a number of settings:
• Single (cures with trailing lamp only)
• Double (cures with both lamps)
• Post (cures with the leading lamp only)
The lamp settings are user-adaptable. Also, for multi-layer printing, you can increase the curing time and reduce the intensity of UV light.
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In addition to these lamp settings, the cure energy can also be varied. To minimize head strikes with unknown substrates you are ad-
vised to start with a low curing energy and raise cure energy gradually as needed. The cure energy can be set at
• Low: 20%
• Medium: 40%
• High: 60%
• Maximum: 100%
• Custom: User-defined percentage.
95% of UV-curable printers have only curing UV lamps. Only the Inca Spyder 150 and a few other innovative machines have a pinning
lamp before the curing lamp.
201. What technology is used in curing lamps: microwave, continuous (mercury arc), LED, or flash (pulsed Xenon)?
Mercury-arc lamps.
Virtually all UV printers use mercury arc UV lamps. Only NUR and a few others use microwave UV lamps. Pulsed Xenon lamps have failed
the few times they were tried (an early VUTEk UV printer circa 2000-2001; a cheap Oce Arizona 60uv printer). LED lamps are now being
tried in several UV printers, such as by Sun LLC (in Russia), Mimaki, and Roland. The Gerber Solara ion uses a rare type of long relatively
cool UV lamp that is not used by any other wide-format inkjet printer manufacturer.
Most normal UV printers have two lamps, one for each direction of printing. Some cheap Chinese printers use only one lamp. Mimaki
uses one lamp on several of their narrow-format UV printers to avoid the lawnmower effect that is caused by bi-directional printing
(bi-directional print requires two lamps, one for each direction of ink laydown by the printer carriage).
In spite of the industrial size of the UV curing lamps, there is minimum light leaking.
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The Agfa :Anapurna 100 (a printer that was never finished due to being too complex), and its recent replacement, the :Anapurna XLS,
have three sets of lamps: all curing, not for pinning. The Lüscher JetPrint, due to its über-dimensional size, may also have needed more
than two lamps (whatever it had did not function fully adequately).
203. What shuts the lamps off? For example, after so many minutes of not being used; or if they overheat?
The hood and cabinet doors are interlocked. If opened, the whole printer will cease working (and therefore, lamps go off) If there is a
head crash, the lamps will also go off.
This is a crucial question, and one seldom asked elsewhere: if your UV lamps need to be turned off after the printer being unused for
5 to 10 minutes, then your lamps’ life gets used up quickly (if they are mercury arc). Each strike (turning the lamp off and on one time)
can lower the life of the lamp by one or two hours. So ideally you want a kind of UV lamp system where the lamps can stay on as long
as possible to avoid having to turn them off and on all day long.
Another downside of having to turn the lamps off is that you then have to let them cool down, and then have to let them heat up again.
Most of these issues are with mercury arc lamps (due to their intense heat). You don’t have these problems with LED lamps.
204. How long does the lamp last, in terms of hours of operation?
Each lamp lasts an average of 800 to 1000 hours.
One of the safety aspects designed in the EFI VUTEk GS3200 is related to UV lamps: whenever a door in the printer is opened, the shutters close
and the printhead carriage stops. This prevents the operator from suffering eye damage with UV light.
UV LAMPS: Cooling
The shutters on the Gandinnovations printer are pneumatic, so don’t stick as often as mechanical shutters. DuPont Cromaprint 22uv
printer seemed to have issues with its shutters getting stuck (either stuck open or stuck shut). So DuPont had to switch to another solu-
tion. We occasionally hear of shutters of other brands of printers sticking as well. Indeed one company said they don’t use shutters at all
due to the possibility of them not opening or closing. Making them pneumatic resolves many of these issues. Of course one reason for
not using shutters is to save cost. Most Chinese printers and low-cost UV printers made in the US and elsewhere may skip shutters.
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But it may be safer to have no shutters at all rather than have shutters, then depend on them, and if they fail nonetheless, then the UV
lamps can set the printer on fire.
209. What other fans are there in the printer, or exhaust ports?
The only other fans are on top of the printer (the exhaust outings).
210. How long does it take to cool the lamps down before you can touch them to change them?
No more than 5 minutes.
The operator’s instructions for the Durst Rho 800 Presto is the first user’s manual where I have seen mention of how long you need to
let the lamp cool down enough to touch it safely: they recommend one hour.
2
3
1
3
5 4
These are some of the components of the UV lamp assembly. High voltage connector (1), Connector to fan speed controller board (2), UV lamp
fans (3), Fan power connectors (4), Lamp air filters (5).
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GENERAL CONSIDERATIONS
217. How many printers of this model are in use; in the USA; in the rest of the world?
Around 100 in the world.
It is crucial for a printshop owner, who is making their short list of which printers to consider buying, to know how many printers of
each brand have been sold.
218. When people are considering buying this printer, what other printer(s) are they also looking at?
Potential buyers are also looking toward Durst and HP. The Polytype Virtu RS series might also be a competitor but the Swiss company
is not as strong in the market as Durst and HP.
Between 50% to 75% of all UV printers at a typical trade show exhibit at least bi-directional handing.
Some printer booths cheat and set their printer on uni-directional mode. Normally this gets rid of bi-directional banding.
But you may also have banding from a nozzle being out.
Or there may be banding from inaccurate feeding of the material or movement of the gantry between passes.
More passes tend to get rid of banding on almost any and all inkjet printers. Of course it helps if the machine is precision engineered
so you don’t get much banding at four passes and above. Banding at two passes is normal. You can eliminate pass-overlap banding by
using an interweaving technique (which Mutoh developed and now Roland and others have copied).
This matrix in the demo room shows the output quality in the different print settings. The samples below are printed at 600 dpi. The upper
samples are printed at 1000 dpi. The first column at the left is printed with High Smoothing; the middle column is printed with Low Smoothing
and the last column to the right is printed with No Smoothing setting.
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As explained earlier, Smoothing is the technology by which banding issues are eliminated through blending the ink drops as they are fired by the
printheads.
224. What causes edge splatter (in addition to satellite drops)? Ink splatter is visible either where a dark color adjoins a
lighter area, or with black text against a lighter background.
You see this on all text or wherever one color changes to another color. One tech support person suggested splatter was caused by
satellite drops. Evidently a high firing frequency develops more satellite droplets. It was also suggested that splatter could come from
mis-registration between heads, or simply bad ink.
225. Is text sharp or fuzzy? What is the smallest text that you can easily read?
It is sharp; 4 point text is perfectly readable.
Five years ago the dot pattern was like sand. This is because each ink droplet is cured as a physical bit of ink, on top of the substrate. UV
ink is not supposed to sink into the substrate (water based ink goes deep into the media to interact with the chemicals in the coating
that are made specifically for water-based ink).
Today, in 2010, the better UV-cured printers have a texture that is not as sandy or textured as in past years. But the printing mode
(speed) and other factors may influence what the surface texture is really like.
Small text is tested with black over white background and white over black background to see the different results.
226. What about the dot pattern? Is the image grainy (like sand) or is the image smooth as you would expect of a pho-
tograph?
Five years ago the dot pattern was like sand. This is because each ink droplet is cured as a physical bit of ink, on top of the substrate. UV
ink is not supposed to sink into the substrate (water based ink goes deep into the media to interact with the chemicals in the coating
that are made specifically for water-based ink).
Today, in 2010, the better UV-cured printers have a texture that is not as sandy or textured as in past years. But the printing mode
(speed) and other factors may influence what the surface texture is really like.
How good is the adhesion of the ink? To what degree can we expect cracking of the resultant image if on a flexible substrate?
I will answer the adhesion, abrasion, and chipping all at once: problematic materials with some inks (such as some recent versions of
Sericol) may have issues of one kind or another with DiBond, Plexiglas, Coroplast, Sintra, and Styrene.
230. What about abrasion (scratch) resistance? How susceptible is the ink to abrasion?
Inks are guaranteed for 2 years.
Conclusions
Pros Cons
With its 321.3 cm (126.5”) the EFI VUTEk GS3200 is the widest UV- Although the possibilities with this printer are wide, EFI has been
cured combo printer, considering that most other combo printers rather conservative regarding the type of substrates used with
have a print width of only 250 cm (98.4”). Other UV-cured inkjet the GS3200. All of the applications exhibited at trade shows and
printers such as the Durst Rho 800, Rho 900 and Rho 1000, the HP at the demo room are printed on media especially manufactured
Scitex FB950, the Polytype Virtu RS35/48, and Agfa :Anapurna L to be printed on with inkjet printers. This is not necessarily bad,
and XL have a print width that does not exceed the 250 cm. but there has not been any other application outside traditional
signage advertised for this printer. No glass, no tiles, no wood, just
The printer was designed as a very versatile machine, and as such, foamboard, Styrene, vinyl, or similar inkjet media.
several aspects were taken into account regarding the handling of
rigid and flexible media. For example, for roll-fed media, the waste
is minimized because you don’t need to fix the front end of the Potential issues (not serious enough
media up to the take-up roll, since tension is created between the to be a fully negative point)
vacuum system and the feeding roller. Except for the position of the monitor, it is somewhat difficult to
know which is the front and which is the back. This is even more
The MediaMaster is a very sophisticated mechanism that acceler- difficult when the MediaMaster is placed in front of the printer.
ates production times, although the investment is considerable:
another US$125,000. On the subject of the MediaMaster, the de- Experienced operators will know how to service Spectra, or Koni-
velopment has not stopped at its current stage, and there will be caMinolta printheads. But Seiko heads are not common in UV
a second generation of this mechanism which will be able to take printers. In fact, the only other printer I know that uses Seiko print-
the boards directly from the pallet. heads is the 3-meter Challenger solvent printer.