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Formation of the Printing Elements in the Photopolymer Material Used in

Flexography

Article in Key Engineering Materials · May 2014

DOI: 10.4028/www.scientific.net/KEM.611-612.883

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Key Engineering Materials Vols. 611-612 (2014) pp 883-891
Online available since 2014/May/23 at www.scientific.net
© (2014) Trans Tech Publications, Switzerland
doi:10.4028/www.scientific.net/KEM.611-612.883

Formation of the Printing Elements in the Photopolymer Material Used

in Flexography

Sanja Mahović Poljaček1,a*, Tamara Tomašegović1,b, Tomislav Cigula1,c,

Miroslav Gojo1,d, Diana Milčić1,e
1
Getaldićeva 2, 10000 Zagreb, Croatia
a*
smahovic@grf.hr, ttomaseg@grf.hr, ctcigula@grf.hr, dmgojo@grf.hr, edmilcic@grf.hr
b

Keywords: Flexography, photopolymer, LAMS, printing element, bump curve.

Abstract. Starting point of this paper is photopolymer printing plate used for flexographic printing.
It is used for transfer of the printing ink onto the printing surface during the reproduction process.
Photopolymer printing plate consists of several layers: polyester basis, photo sensitive polymer
material and LAMS - Laser Ablation Mask. In the platemaking process the photosensitive material,
which will form a printing plate, has to be several time exposed to different radiation in order to
obtain a functional printability performance. LAMS layer has a role of masking in the exposure
process. Upon pre-exposure, LAMS layer has to be removed by laser ablation only at the surfaces
where photopolymer printing plate needs to be exposed. After ablation the exposures to UV lights
follows and the plate will be finished with chemical removal of the unexposed parts of the polymer.
Functionality of the finished printing plate has to be characterised and monitored in every procedure
step because the formed image element on the printing plate has a major influence on the quality of
the finished printed product. In this paper observing of the changes in the polymer material which is
caused by exposure through LAMS layer will be performed. The aim is to measure the surface
openings on the LAMS mask and to measure coverage values (percentage of the image elements on
the observed area of the printing plate) on the polymer material formed by exposure through the
LAMS. Measuring will be made by image analysis software based on microscopic images of the
control fields of differing halftone values. It is assumed that there will be a correlation between the
LAMS openings and formed image elements on the printing plates. Preliminary results indicate that
certain differences in image elements can be detected and are probably the consequence of the
different amount of irradiated surface of the polymer material. Since the polymer material which
forms the printing plate should be stable in the graphic reproduction process, results of the paper
will explain the influence of UV exposures on polymerisation process and on the functional
printability performance of the plates.

1 Introduction

Flexography is a direct rotary printing technique which uses a relief printing plate made of
elastomeric photopolymer material. Printing plate is the material used to transfer the image from the
original digital file to the printing substrate (paper, foil, etc.) [1]. The composition of the UV-
sensitive flexographic printing plate includes monomers, photoinitiator, copolymers (most common
SIS/SBS copolymer), UV stabilizer and plasticizer, formulated to meet mechanical and qualitative
requirements in the graphic reproduction process [2,3]. The imprint in flexography is based on the
geometrical difference between the printing and non printing areas. The flexibility of the
flexographic printing plate is its main advantage. It enables printing on a wide range of materials,
such as paper, paperboard, corrugated board, films, laminates, foils and metal [1,4]. With material
and technology development in the last decade, a great improvement has been made in the
application of newly formed materials and in the flexographic printing plate making process as well.
Digitalized printing plate production procedure – Computer to Plate (CtP) has enabled the control of
the formation of the printing elements and their surface and mechanical properties [1]. Therefore,
final product of the high quality can nowadays be obtained in flexography.

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884 Material Forming ESAFORM 2014

1.1 Processing of the LAMS-based flexographic printing plates

One of the most common methods of image transfer from the computer file to the printing plate is
based on Laser Ablated Layer Mask (LAMS) technology. When processing printing plates with
LAMS technology, the black mask layer - LAMS - must be ablated by means of a laser on the image
areas of the printing plate. After ablation process, printing plate is exposed to UV wavelengths [5].

Fig. 1. Processing of the LAMS-based flexographic printing plate: a) back-exposure,

b) ablation of the LAMS, c) main exposure, d) rinsing, e) drying, f) post-treatment

Fig. 1. presents the LAMS-based printing plate production process. After the back exposure
performed in order to create the base layer for the printing elements (Fig. 1a), LAMS is removed by
laser ablation from the image parts of the photopolymer material (Fig. 1b). Fig. 1c presents the main
exposure to UVA radiation, where printing and nonprinting areas are formed. The exposed parts
polymerize and become insoluble in the defined rinsing solution (organic solvent or water). After
the main exposure follow the rinsing of the unexposed parts in the photopolymer material (Fig. 1d)
and drying (Fig. 1e). The printing plate is finished after the post-treatment where the plate is
exposed to UVC radiation (Fig. 1f) in order to terminate the photopolymerization process and
obtain the optimal surface properties of the printing plate [6,7].
However, during the period of laser ablation and the period of UV radiation, photopolymer material
is exposed to the destructive influence of the oxygen. Oxygen disables the photopolymerization,
which results with the solubility of the tops of printing elements in the rinsing solution. The
consequence can mostly be seen in the whole tone range, but it is detectable primary in the
highlights. The results are poorly and incompletely formed small printing elements which are unable
to transfer the printing ink to the printing substrate correctly. Therefore, corrections of the coverage
values in the highlight area of the original image must be performed in order to make those printing
elements reproducible [6].

1.2 Bump curves in flexographic printing plate production

The correction which should be applied in order to overcome the influence of the oxygen on the
printing plate is performed on the digital image file. It is called the “bump curve”. The bump curve
increases the coverage value of the highlights in order to make the smallest printing element
correctly formed. For example, it is possible to enlarge the opening in LAMS (at e.g. 7%) in order
to obtain 1% of coverage value on the printing plate [8].

Fig. 2. Various types of bump curves applied in flexography

Fig. 2. presents the different types of bump curves which can be applied to the digital file,
depending on areas of the transition between the tones on the image and representation of highlights
 Key Engineering Materials Vols. 611-612 885

and mid-tones on the image. It is important that the transition between the tones and the gradient on
the corrected image are fluent.
Besides the adjustment of the smallest printing element to the reproducibility of the photopolymer
material, it is also important to adjust its dimensions to the dimension of the anilox roller cell.
Anilox roller is in direct contact with the printing ink during the reproduction process, and it has a
role of transferring the optimal amount of the printing ink to the printing plate. Too small printing
element could drop in the cell of the anilox and transfer too much printing ink to the printing
substrate [8].
From the fact mentioned above it can be seen that the correction of the highlights on the
flexographic printing plate is necessary for the quality of the final product. Therefore, the bump
curves which have a major importance in the formation of the printing elements in the
photopolymer material will be studied in this paper.

2 Experimental settings

2.1 Preparation of samples

For this research, solvent-washable, SBS copolymer LAMS-based printing plate was used. Two
types of samples were prepared: five samples of unfinished printing plate with different bump
curves applied, where only ablation of the LAMS on the image area was performed, and samples of
finished printing plate corresponding to the LAMS samples. The differences between bump curves
applied can be seen in Table 1.

Table 1. Coverage values on the printing plate and size of openings on LAMS for different bump
curves
Coverage value of
Opening on LAMS
the smallest printing
Sample for the smallest
element on the
printing element
printing plate
2BU 6 pixels 2%
4BU 12 pixels 4%
6BU 18 pixels 6%
8BU 24 pixels 8%
10BU 29 pixels 10%

Samples of finished printing plates were processed in standard conditions proposed by the printing
plate manufacturer.
The image transferred to the samples was a control wedge with fields of coverage values from 1%
to 100% with step of 10% coverage value between the fields. Additionally, fields in highlight area
had a smaller step: coverage values of 1, 3, 5, 8, 10 and 15 % were represented on the control wedge
in order to examine the formation of the small printing elements in detail.

2.2 Measurement methods and devices

In order to monitor the formation of the small printing elements (highlights), the areas of the
openings on LAMS and the percentage of the image elements on the observed area of the printing
plate (coverage value) were measured. Also, the cross-section of the small printing elements was
captured and displayed.
The device used for the measurement of LAMS openings and printing elements was Olympus
Metallurgical Microscope BX51 [9]. Olympus BX51 is a microscope with the ability of capturing
images under magnification up to 1500x, with program support for image adjustment and analysis.
It enables the calculation of the coverage values on the printing plate and the imprints, as well as the
886 Material Forming ESAFORM 2014

measurement of the printing element’s area and diameter. In Fig. 3. one can see the printing element
of the flexographic printing plate of 10% coverage value captured with Olympus BX51 under the
magnification of 1000x.

Fig. 3. Flexographic printing element Fig. 4. Topography of flexographic printing

of 10% coverage value captured by elements of 50% coverage value displayed by
Olympus BX 51 microscope AniCAM 3D microscope

For the analysis of the pritning element's formation, 3D microscope AniCAM was used [10].
AniCAM is a microscope used for the flexographic pritning plate, gravure printing cylinder and the
anilox roller analysis. It can display the 3D image of the surface by capturing its layers based on
changes in focus, and then merge them. Fig. 4. presents the 3D display of the flexographic printing
plate surface. Different colors are assigned to different height (red – highest area of the surface, blue
– deepest area). AniCAM can also display the cross-section of the selected area, which was
important for the monitoring of the printing element's formation with different bump curves applied.

3 Results and discussion

Results of the LAMS openings and corresponding printing element’s dimensions for lowest and
highest value of bump curves applied can be seen in Fig. 5. and 6., respectively.

Fig. 5. Comparison of the area of openings on LAMS and area of the printing element with the
application of bump curve 2BU

In Fig. 5. one can see that areas of the printing plate are lower than the areas of the openings on
LAMS for whole coverage value range for 2BU bump curve. This is particularly important for low
coverage value area (1% - 10% coverage value). It is obvious that printing elements in highlight
area have not been formed below the 5% of coverage value. The consequence of this would be the
absence of the highlights on the imprint, and therefore the poor quality of the reproduction. The
results indicate that the influence of the oxygen on the formation of printing elements when 2BU
curve is applied is significant. On the other hand, the insufficient amount of radiation which reaches
 Key Engineering Materials Vols. 611-612 887

the photopolymer surface through the small openings on LAMS could have the influence as well.
Other parameters which could influence the printing element’s dimension – particularly
undercopying and the contraction of the photopolymer material are not significant, since printing
elements didn’t form at all.
This indicates that by applying the 2BU curve, the printing elements in the highlights have not been
formed correctly. Therefore, 2BU curve is not applicable for this type of photopolymer material.

Fig. 6. Comparison of the area of openings on LAMS and area of the printing element with the
application of bump curve 10BU

Printing elements produced by application of 4BU, 6BU and 8BU show the increase of the coverage
value in highlight area, but are still not correctly formed. Only the application of bump curve with
highest value –10BU (Fig. 6.), ensures correctly formed tops of the printing elements and correct
height, therefore ensuring their optimal functional properties.
The difference between the dimensions of openings on LAMS and the printing elements in mid-tone
and shadow area are similar for all applied bump curves. That indicates that the oxygen has not got
the major impact in formation of the higher coverage areas. However, the contraction of
photopolymer material and the material properties have greater impact for the printing element
formation.

Fig. 7. Comparison of the area of openings on LAMS for different bump curves applied in
highlights

In Fig. 7. one can see the differences in areas of openings on LAMS for different bump curves in the
highlight area. The area of openings on LAMS for 1% coverage value on 2BU curve is cca. 800
µm2, and cca. 3200 µm2 for 10BU curve. As the nominal coverage value increases, the difference
between highest and lowest bump curve decreases. For the 20% nominal coverage value it equals
cca. 1500 µm2.
888 Material Forming ESAFORM 2014

Fig. 8. Comparison of the area of the printing elements for different bump curves applied in
highlights

Fig. 8. presents the differences between area of printing elements produced with different bump
curves in highlights. Fig. 8. shows the increase in the area difference in higher coverage value area
(15% - 20%), which is opposite of the area trend in Fig. 7. This indicates that the formation of the
printing elements is not in linear correlation to the openings on LAMS, as with the increase of the
coverage value the undercopying starts to impact the printing element formation [11]. Therefore,
when applying a bump curve type, one should also consider its influence on the formation of
printing elements of higher coverage value.
Cross-sections from right and left side of the smallest printing element produced on the printing
plate samples (1% coverage value) are displayed in the Fig. 9. to 11.

Fig. 9. Cross-section of printing elements at 1% coverage value with application of bump curve
2BU

The cross-section of the printing element of 1% coverage value presented in Fig. 9. shows that the
printing elements have not been formed. Printing area cannot be clearly distinguished from the
nonprinting area, and therefore the elements will not have the necessary functional properties. Also,
the height of the relief is only between 15.4 and 21.9 µm, which is not enough to achieve optimal
printability in the reproduction process.

Fig. 10. Cross-section of printing elements at 1% coverage value with application of bump curve
6BU

In Fig. 10 one can see the cross-section of printing elements produced by application of 6BU curve.
Although the printing elements have the sufficient height to achieve optimal printability, their
formation is not completely correct. The difference in the height of two sides of the element is 12.5
µm, which could result with the deformations of the screen element on the printing substrate.
 Key Engineering Materials Vols. 611-612 889

Additionally, the shape of the printing elements has not been correctly formed (printing elements are
too narrow), which could result with the instability in the reproduction process due to the pressure
during the printing. The outcome would be deformed screen elements [12].

Fig. 11. Cross-section of printing elements at 1% coverage value with application of bump curve
10BU

Correctly formed printing elements of 1% coverage value are produced by application of the bump
curve 10BU (Fig. 11.). The heights of both profile sides of printing elements are similar, and the
base of the printing element is wide, which ensures the stability in the reproduction process. The
influence of the oxygen is still visible, since the printing area at the 1% coverage value of the
printing plate sample 10BU is similar to the printing area of printing plate sample 6BU.
Nevertheless, printing elements produced by application of the bump curve with highest value are
optimally formed.

Fig. 12. 3D display of printing elements of 1% coverage value with application of bump curve 2BU,
6BU and 10BU, respectively

The topography of printing elements of 1% coverage value produced by application of 2BU, 6BU
and 10BU (Fig. 12.) confirms the results presented above and shows the difference in the printing
element’s formation. It is visible that the application of 2BU curve does not result with functional
printing elements. As it is visible in Fig. 10. and 11., the main difference between the 6BU and
10BU printing plate samples is in the base of the printing element. In the flexographic reproduction
process, printing elements are deformed because of the pressure [13]. If the printing element base is
not wide enough (printing plate sample 6BU), the deformation will be more expressed, causing the
transfer of the excessive ink amount to the printing substrate. On the other hand, the shape of the
printing elements on 10BU sample will result with their stability in the printing process and the
deformation of the screen element on the imprint will be minor. Therefore, when applying the bump
curve to the digital file, one should, besides the correct formation of the printing element’s top, also
consider the shape and stability of the whole printing element. This would result in the optimal
coverage value transfer throughout the graphic reproduction process [14].

4 Conclusions
This research was performed in order to examine the differences in low coverage printing element’s
formation when using different values of bump curves. Also, the aim was to analyze the impact of
different factors influencing the photopolymer material during the printing plate exposure through
the LAMS mask. After obtaining the results from the differences in the dimensions of the openings
890 Material Forming ESAFORM 2014

on LAMS and the dimensions of printing elements, as well as the analysis of the printing element’s
profiles and surfaces, one can come to the following conclusions:
- undercopying has not got the impact on the printing elements in highlights (< 10% coverage
value), since the degradation of the material caused by the influence of the oxygen is expressed,
causing the incomplete formation of the printing elements. Undercopying influences the printing
elements in higher coverage value area, when they are completely formed and have the necessary
functional properties.
- undercopying can be a factor which could enhance printing element’s stability, especially in the
coverage area of highlights, where printing element’s top is correctly formed, but the base of the
element is too narrow. By adjusting the dimension of the openings on LAMS, the base of the
printing element can be widened, therefore ensuring the optimal mechanical properties in the
reproduction process.
- contraction of the photopolymer material in combination with the destructive influence of the
oxygen results in lower coverage values on the printing plate compared to the openings on LAMS in
the whole coverage value range. The sensitivity of the particular photopolymer material to UV
radiation is also the cause for this phenomenon, since the photochemical reaction is apparently not
conducted completely in the whole area opened on LAMS.
- influence of the oxygen on the photopolymer material in LAMS workflow cannot be avoided.
Therefore, it is of major importance to adjust the bump curve in a way that the top of the small
printing element has correct area, and that the printing element has an optimal shape and profile.
This will enable the stability in the reproduction process and minimize the deformation of screen
elements on the imprint.
Reproduction quality in flexography is still improving. The formulations of new materials with
enhanced reproduction properties and the improvements in workflows enable the production of
high-quality imprints. The quality control of the printing plate is usually focused on monitoring of
the coverage values. Nevertheless, control of the printing element’s shape in 3 dimensions is a step
which helps to define the impacts on its formation, and could help to improve the quality of the final
graphic product. Together with the surface coverage measurements, it could optimize the printing
plate production workflow and further adjustments of the printing plate to the specific reproduction
system.

5 References
[1] J. Page Crouch, Flexography Primer, 2nd edition, PIA/GATF Press, Pittsburgh, 2005.
[2] R. Knoll, Photopolymerizable flexographic printing elements comprising SIS/SBS mixtures as
binder for the production of flexographic printing plates, Pat. US 6,531,263 B2 (2002)
[3] T. Matsubara, R. Oda, Block copolymer composition for flexographic printing plates, Pat.
20,110,308,412 (2011)
[4] H. Kipphan, Handbook of Print Media, Springer, Berlin, Germany, 2001.
[5] R. Bodwell, J. Scharfenberger, Advancing flexography: The technical path rorward, DuPont
Packaging Graphics, 2011.
[6] T. Tomašegović, S. Mahović Poljaček, T. Cigula, Modification of flexographic printing
plate’s surface properties by variation of UVC finishing, XI Symposium on Graphic Arts,
Pardubice, 2013, 59.
[7] T.Y. Lee, C.A. Guymon, E. Sonny Jönsson, C.E. Hoyle, The effect of monomer structure on
oxygen inhibition of (meth)acrylates photopolymerisation, Polymer, Volume 45, Issue 18,
Elsevier, 2004, 6155–6162.
[8] O. Brajnović, Adjustment of the photopolymer printing forms to match new qualitative
requirements, Master thesis, Faculty of Graphic Arts, University of Zagreb, Zagreb, 2011.
[9] Information on: http://www.well.ox.ac.uk/_asset/file/olympus-bx-51-brochure.pdf
 Key Engineering Materials Vols. 611-612 891

[10] Information on: http://www.troika-systems.com/English/_downloads/AniCAM

m3D_Scanning_Microscope_E.pdf
[11] ISO standard 12647-6, Graphic technology - Process control for the production of half-tone
colour separations, proofs and production prints -Flexographic printing, 2006.
[12] T. Tomašegović, S. Mahović Poljaček, T. Cigula, Impact of screen ruling on the formation of
the printing elements on the flexographic printing plate, Acta Graphica. 1-2/13, 2013, 1-12.
[13] G. L. Laurent, Analysis of the Correlation Between the Print Quality Required in Flexography
and the Tolerances in Materials and Paper Manufacturing in Terms of Printability, Royal
Institute of technology, Department of Numerical Analysis and Computer Science, Sweden,
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[14] S. Mahović Poljaček, T. Cigula, T. Tomašegović, Meeting the quality requirements in the
flexographic plate making process, Proceedings of the 44rd conference of the International
Circle of Educational Institutes for Graphic Arts Technology and Management, Budapest,
2012., 8.
 Material Forming ESAFORM 2014
10.4028/www.scientific.net/KEM.611-612

Formation of the Printing Elements in the Photopolymer Material Used in Flexography

10.4028/www.scientific.net/KEM.611-612.883

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