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Introduction The LEC series printer/cutter supports CMYK + white and clear ink configuration. The white ink can be used as an undercoat to print vibrant images on clear or metallic substrates. The clear ink can be used as a gloss or matte spot varnish for highlights or for simulating embossing effects by overprinting multiple layers of ink. These special printing and cutting features are accomplished by using specific spot colors in your design.

This document describes the process of creating a box prototype and covers the following topics:

1. Required tools 2. Assigning special spot colors for printing with white and clear ink 3. Assigning special spot color for creasing and die cutting lines 4. Setting the job in VersaWorks for creasing, printing and die cutting with VersaUV LEC printers 5. Sending the job to the LEC printer/cutter

RDG_WHITE – Objects filled with RDG_WHITE spot color will be printed with White ink.

RDG_GLOSS – Objects filled with RDG_GLOSS spot color will be printed with Clear ink.

CutContour – Use this stroke color for crease lines

PerfCutContour – Use this stroke color for die lines

Substrate

White

CMYK

Clear

Section view of a printed media

Working with LEC and VersaWorks

Folding Carton Workflow

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Required Tools for Creasing and Die Cutting The following tools will be required for creasing and die cutting. These tools are not included with the printer and must be ordered separately from your dealer or directly from Roland’s online store (www.rolanddgastore.com). The LEC printer/cutter can be used to die cut card stocks up to 18pts.

1. Creasing tool (US-CREASE-1) 2. 60 degree cutting blade (ZEC-U3050)

Tech Note: Please make sure the cutting parameters (blade offset) are set correctly when using the tools above. The creasing tool has an offset of 0 mm and the 60 degree blade, 0.5 mm. The cutting parameters should be set from VersaWorks which is described in detail later in this document.

Installing the VersaWorks Swatch Library in Illustrator If you have VersaWorks in your computer, follow the steps below to install the swatch libraries pre-configured with special spot colors in Adobe Illustrator. If you do not have VersaWorks, follow the steps described in Creating Swatches for White, Clear, Contour Cutting and Perforated Cutting.

1. Launch Windows Explorer and navigate to C:\Program Files\Roland VersaWorks\Swatch\Illustrator folder.

2. Select all files in this folder, right-click with the mouse and select Copy.

3. Navigate to C:\Program Files\Adobe\Adobe Illustrator CS4\Presets\en_US\Swatches folder.

4. Right click on Swatches folder and select Paste.

Tech Note: The folder structure may be slightly different depending on the version of Illustrator.

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5. Launch Adobe Illustrator and navigate to Window > Swatch Libraries > Roland VersaWorks to display the Roland VersaWorks swatch library. Note that PerfCutContour swatch for die cutting is not included by default in this swatch library. Please follow the steps described in Creating Swatches for White, Clear, Contour Cutting and Perforate Cutting to create the swatch.

Creating Swatches for White, Clear, Contour Cutting and Perforated Cutting If you do not have VersaWorks, follow the steps below to create the swatches for White, Clear and Contour Cutting. If you have VersaWorks in your computer, follow the steps described in Installing the VersaWorks Swatch Library in Illustrator.

1. In Illustrator, select New Swatch from Swatches palette.

2. Create the spot color for White and Clear inks

3. Create the spot color for creasing and die cutting.

Swatch Name: RDG_WHITE for white,

RDG_GLOSS for clear. Swatch color names are case sensitive. Please type the names exactly as shown.

Color Type: Must be Spot Color

Swatch Name: CutContour for creasing and PerfCutContour for die-cutting. Swatch color names are case sensitive. Please type the names exactly as shown.

Color Type: Must be Spot Color

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Applying the White, Clear, CutContour and PerfCutContour Swatches in the Artwork Roland strongly recommends having white, clear; crease and die line objects organized in distinct layers for easier manipulation and visualization. Depending on the printing features that are used, some objects will have to be isolated and saved in a separate file. Having them organized in distinct layers per special feature will greatly facilitate this process. Crease lines will be always required to be saved as a separate file as the cutting tool must be replaced on the printer. Saving into separate files must be the last step before printing to ensure that objects in different files are registered correctly.

1. Apply the RDG_WHITE and RDG_GLOSS swatches to the objects in the artwork that needs to be printed with white and clear ink respectively.

Tech Note: The order of printing is determined by the printing mode in VersaWorks and as a general rule, the order of the objects in the artwork does not affect the order of printing.

2. Apply the CutContour and PerfCutContour swatch to the stroke of crease lines and die lines respectively.

Tech Note: The crease and die lines must be vector objects and placed on top of any other object. CutContour is used for creasing as this special color controls the movement of the cutter while applying a constant pressure. PerfCutContour alternates the cutting pressure between strong and normal. The strong pressure should be carefully calibrated to cut through the substrate while leaving small tabs that are cut with normal pressure, preventing the finish object from falling from the substrate.

RDG_WHITE RDG_GLOSS

CutContour

PerfCutContour

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3. Save the design following these guide lines: a. The crease lines must be isolated and saved as a

separate file. b. If you have different finishing options using the clear ink

such as matte, gloss or embossing; objects must be grouped and saved as a separate file per finishing option.

c. White and Color data should be saved together for best registration between these colors.

d. The die lines can be included with the last printing job (typically special finishing jobs with clear ink or color jobs if no special finishing option is required) or isolated and saved as a separate file.

In this example, the job will be saved as three (3) PDF files as follow:

Crease data (Crease.pdf) White + Color data (W+Color.pdf) Emboss + Die Cut data (Emboss+Die.pdf)

Each file was saved while enabling the relevant layers and disabling the ones that are not needed.

Tech Note: When saving the job in multiple files, it is important to use file formats that register the page size information such as PS or PDF. EPS file does not register the page size information and may cause registration issues when printing.

When saving as a PS file, select the RolandVW for the printer and click on the Custom button in Advanced > Overprint and Transparency Flattener Options > Preset if it is selectable and set the following options:

a. Set the Raster/Vector Balance slider to 75. b. Uncheck the Convert All Strokes to Outlines option

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Determining the Ideal Cutting Pressure for Die Cutting The LEC printer/cutter provides easy access to cutting adjustments functions through the printer menu. Follow the steps below to determine the ideal pressure for die cutting. Note that excessive cutting pressure may cause the cutter blade and cutter protection strip to wear prematurely.

1. Set the 60 degree blade on the printer. 2. Press the CUT CONFIG button. 3. Use the LEFT or RIGHT button to navigate through the cutting parameters and

use the UP and DOWN buttons to change the parameters. Press ENTER to apply the changes. FORCE : down force (pressure) for the blade. Start at 50 gf to be safe SPEED : cutting speed. Set this to 10 or 15 cm/s. OFFSET : blade offset. Set this to 0.500 mm if you are using the 60 degree blade. The blade offset is typically printed on a label on the case. UP-SPEED : blade’s speed in up position. Leave at the default value.

4. Load the card stock on the LEC printer/cutter. Cutting a surface covered with UV ink requires higher pressure and the cut tests should be performed on top of a printed surface. Skip to step 8 if you are not cutting over a printed area.

Tech Note: When loading the media, select PIECE before pressing the SETUP button and make sure the media is loaded without buckling. If the media buckles during SETUP, the same issue will occur during printing which may cause head strikes and damage the print head.

5. Press the MENU button on the printer and then the DOWN button until the CUT TEST PRINT is displayed. 6. Press ENTER. The printer will print a black rectangle for performing the cut tests over a printed surface. 7. After the printer finishes printing, press the LEFT button and exit from the CUT TEST PRINT mode. 8. Press TEST CUT. The printer will execute the cut test pattern (a square and a circle). 9. Check if the circle can be completely and easily removed from the media. 10. Press CUT CONFIG and adjust the PRESSURE and press ENTER. 11. Use the arrow buttons and move the cutter blade to the left of the previous test cut pattern and press BASE

POINT. 12. Repeat the steps 8 to 11 until a cutting pressure that allows the circle to be completely and easily removed

from the media is found. 13. Take note of all cutting parameters for later use.

Printing the Job from VersaWorks The procedure below describes the process of producing a box prototype off the LEC printer/cutter with minimal user intervention. This box prototype includes a white undercoat to produce vibrant images on metallic card stock, a unique embossed texture, crease lines and die-cut. The three (3) files will be queued in VersaWorks and released in two (2) steps for allowing for changing of creasing and cutting tools.

1. Drag and drop the artwork files in the VersaWorks queue.

Tech Note: You can also select File > Add Job to Queue A (or B) and select the file.

Add the files in the order that they will be printed for a streamlined workflow. In order to not cause damage to the printed surface, the jobs should be processed in this order: a. Creasing job b. White and color data job c. Embossing and die cut job

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2. Select the Crease job and navigate to Job > Settings to open the Job Settings window.

Tech Note: You can also double-click on the job in the queue.

3. Set the following in Layout window: a. Click on Get Media Width b. Set the Scaling or resize the job if necessary c. Set the number of Copies d. Set any other layout options such as Centering, Spacing and

Orientation if necessary

4. Set the following in Cut Controls window: a. Select Cut Only in Operation Mode b. Check the option Return to Origin after Cut c. Check the option Enable Advanced Settings and set the

following parameters: i. Cut Passes: 1 ii. Speed: 5 cm/sec iii. Pressure: 300 gf (adjust this pressure

if necessary) iv. Offset: 0 mm

d. Click OK to close Job Settings window.

Tech Note: Cut Passes can be increased if the maximum pressure of 300 gf is still not enough for folding. On some hard materials, you may still need a straight edge to fold it properly.

Crease job

White and Color data

Emboss and Die cut data

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5. In VersaWorks, select the next job (white and color data – W+Color.pdf) and navigate to Job > Settings to open the Job Settings window.

6. Set the following in Layout window: a. Click on Get Media Width b. Apply the exact same settings used for the crease job.

Tech Note: Make sure the Layout settings are identical on all 3 jobs or the jobs will not register correctly.

7. Set the following in Quality window: a. Select Generic in Media Type b. Select the Print Quality c. Select the Mode (White->CMYK should be selected for this example):

i. CMYK – prints only the color portion a job ii. White->CMYK – prints color and white objects at the same time with color objects on top iii. CMYK->White – prints color and white objects at the same time with white objects on top iv. White – prints only the white portion of a job

Tech Note: Note that the preview shows the white area with a pink hatch fill when a mode with white is selected.

Layout Window Quality Window

8. Set the following in Cut Controls window: a. Select Print Only in Operation Mode b. Check the option Return to Origin after Print c. Click OK to close Job Settings window.

White data

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9. Select the last job (emboss + die cut) and navigate to Job > Settings to open the Job Settings window. 10. Set the following in Layout window:

a. Click on Get Media Width b. Apply the exact same settings used for the previous jobs.

Tech Note: Make sure the Layout settings are identical on all 3 jobs or the jobs will not register correctly.

11. Set the following in Quality window: a. Select Special Effects in Media Type b. Select the Print Quality c. Select Embossing in Mode

Tech Note: There are three finishing options for clear ink as follow: GlossVarnish – prints a single layer of clear ink with gloss finish MatteVarnish – prints a single layer of clear ink with matte finish Embossing – prints the number of layers of clear ink specified in Printer Controls > Overprint and then prints an additional layer with gloss finish. Note that the preview shows the clear ink area with a light blue hatch fill when Special Effects is selected.

Layout Window Quality Window

12. Set the following in Printer Controls window: a. Check the option Use Custom Settings in General b. Set the number of Overprints

13. Set the following in Cut Controls window:

a. Select Print&Cut in Operation Mode b. Uncheck the Return to Origin After Cut and the Return to Origin After Print option c. Check the option Enable Advanced Settings and set the following parameters:

i. Cut Passes: 1 ii. Speed: 10 cm/sec iii. Pressure: 50 gf (Normal Pressure) iv. Offset: 0.500 mm v. Normal Pressure Length: 0.020 in vi. Perforation Length: 0.400 in

Clear data

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vii. Perforation Pressure: Enter the value found in Determining the Ideal Cutting Pressure for Die Cutting session.

Tech Note: Die cutting will be executed according to the parameters as illustrated here.

Printer Controls Window Cut Controls Window

14. Click OK to close Job Settings window. 15. Set the creasing tool in the printer. 16. Select the crease job and navigate to Job > Print to

process to job.

17. Wait until the creasing job is completely processed (printer’s BUSY LED is OFF) and replace the creasing tool with the 60 degree cutting blade.

Perforation Length Normal Pressure Length

Media Blade Perforation Pressure Normal Pressure

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18. Select the remaining two jobs (white + color and emboss + die cut) and navigate to Job > Print to complete the box prototype. The LEC will perform the following operations automatically:

a. Print the White and Color data simultaneously b. Rewind the media back to the origin c. Print the first pass of Clear data d. Rewind the media back to the origin e. Print the finishing pass of Clear for a gloss finish f. Rewind the media back to the origin g. Cut perforations along the die cut lines

19. Remove the media from the printer and then remove the printed artwork from the sheet. Tech Note: If the printed artwork cannot be removed easily from the sheet, verify the following:

a. Double check the perforation pressure settings and readjust if necessary b. Replace the blade if the blade is dented or the tip is not sharp c. Replace the cutter protection strip if it feels rough to the touch