A recent addition to conventional foiling
is dieless foiling. This is also known as Cold Foiling, but it must be
noted that dieless foiling can use heat to transfer the foil.
The most successful and suitable markets have
been the label industry, Reel to reel tubes manufacturing, and fabrics.
This has brought printing and foiling much closer together as regards technology
and costs.
The basic principle is the applying of adhesive
to the substrate prior to the foil being applied. The advantages being
:
1) Running speed
2) No die cost.
3) Very fine detail and screens possible.
4) Ease of set up.
5) Small capital equipment cost.
6) Easy conversion to inline foiling.
To date the most successful method of printing
the adhesive is flexo, although silk screen and letterpress are possible.
Other printing methods are under review.
Cold Dieless Foiling
Free Radical : This is the
most recent process addition, and has to date proven much easier than its
counterpart below. The main difference is that the adhesive is applied
and, prior to any curing, the foil is applied through a nip roller. Then,
while the foil carrier is still on the substrate, both are passed through
a UV lamp to allow full curing together. This works due to a critical thickness
of Finally the foil carrier is separated to leave the foil on the
fully cured adhesive. This has improved the results, gloss level and ease
of set up. The critical semi cure process (below) is no longer needed,
and this is a much easier system to control.

Cationic : This method was
the first to be introduced and uses UV lamps to semi cure the adhesive,
after which the foil is applied through a nip roller and then separated
from the substrate. Finally the "foiled" adhesive is fully cures as it
moves to the material rewind.
The initial semi cure is critical, and can be
difficult to get right.

Hot Dieless
This method uses existing hot foil machines
or stations, but uses a smooth cylinder instead of a die. The adhesive
is applied using one of the print stations, fully cured and then passed
under the hot foil head. The foil is separated by the normal rewind unit
and the process is complete. This method is yet to be perfected for labels
but is fully proven for reel to reel tube manufacturing.
The difficulty with labels and other graphic
applications, is that the foil head needs to be dedicated to dieless foiling
to avoid surface wear from partial image dies. This can cause "missing"
of the foil.
The adhesives have also been problematic in running
and curing properly.
