Large format printing is a versatile and impactful method of creating oversized graphics and designs for various applications. This technology has revolutionised the way businesses communicate visually, offering a wide range of possibilities for advertising, marketing, and information display.
What is Large Format Printing?
Large format printing refers to the process of producing high-quality prints in dimensions that exceed standard commercial printing capabilities.
The printers used are designed to handle materials ranging from 17 to 100 inches in width and beyond. We can print on both flexible and rigid substrates, opening up a world of creative possibilities, whatever your business requirements.
Applications and Uses
Large format printing finds applications across numerous industries:
Advertising: Billboards, posters, and banners
Retail: In-store displays and signage
Architecture and Construction: Blueprints, site plans, and safety signage
Events: Backdrops, stage designs, and promotional materials
Vehicle wraps: Transforming vehicles into moving advertisements
You can see an example of these types of prints on a daily basis, from industrial estates to bustling city centres.
Technology and Innovation: The Large Format Landscape
There’s been significant advancements in the landscape in recent years:
Improved Resolution: Higher print quality and more accurate drop placement
Faster Printing Speeds: Increased efficiency in production
Better Colour Accuracy: Enhanced visual appeal and brand consistency
Automation and Robotics: Greater integration in flatbed systems, increasing precision and enabling continuous production
Cost Considerations
When determining the cost of large format printing, several factors come into play:
Material Costs: Including paper, ink, and finishing materials.
Equipment Costs: The capital expenditure of large format printers.
Maintenance and Running Costs: Cleaning supplies, replacement parts, and electricity consumption.
Businesses can optimize costs by carefully selecting materials, investing in efficient equipment, and streamlining production processes.
Sustainability in Large Format Printing
The industry is moving towards more sustainable practices:
Use of recyclable materials
Smaller printer bodies to reduce environmental impact
Improved functions to reduce waste
If you want to learn more about sustainability in the printing industry, check out our latest post.
These efforts contribute to making large format printing a more environmentally friendly option for businesses.
Future Trends
The future of large format printing looks promising, with several emerging trends:
AI and Machine Learning: Automating tasks and improving design decisions
Connected Construction: Enabling dispersed teams to work from a single source of truth
Robotic Construction Layout Printing: Increasing accuracy and productivity in construction projects
Conclusion
Large format printing offers businesses a powerful tool for visual communication. Its versatility, combined with ongoing technological advancements, ensures that it will continue to play a crucial role in advertising, marketing, and information display across various industries. As the technology evolves, we can expect even more innovative applications and improved efficiency in the years to come.
The trajectory of the print industry in 2024 is defined by innovation, technological integration and sustainability, as businesses look to reduce their carbon footprint whilst improving quality. Here’s a few tips we’ve picked up along the way…
Wastage
Waste is unavoidable in the printing business. Waste can derive from discarded ink cartridges, decommissioned printers, and unused printouts. This exacerbates issues related to paper production such as deforestation, water pollution and methane production (a dangerous greenhouse gas). Sustainable initiatives are constantly evolving to reach the goal of zero waste to landfill. Most methods fall within one of the well known Three R’s: reducing, reusing and recycling.
The Three R’s
Reuse: finding new ways to reuse things you might’ve otherwise disposed of is a great way to green-ify your processes. Utilising excess materials and repurposing for another project can improve your productivity and generate less waste.
Recycle: recycling prevents masses of waste from being buried in landfills. In the UK alone, recycling initiatives lead to a reduction of 10-15 million tonnes of carbon emissions per year, which is equivalent to removing 3.5 million cars from the road. Paper can be recycled five to six times before it reaches its limit. At that stage, it can still be repurposed into products like egg cartons, loft insulation, paints, or even road surfaces.
Ensuring your recycling stations have efficient processes in place maximises their effectiveness and promotes environmental responsibility. Implementing clear sorting guidelines and maintaining regular upkeep is key to successful recycling.
Reduce: reducing unsustainable practices within your business is essential for improving your carbon footprint. Regularly auditing and updating your policies, waste disposal methods, technologies, and materials, and making necessary adjustments can have a significant impact.
implementing appropriate waste disposal solutions for printing machinery and non-recyclable cut-offs.
using recycled paper.
continuously exploring more sustainable production methods in line with industry best practices.
We’ve outlined some of the main ones below:
UV Printing
Utilising UV printing can assist in your pursuit of sustainability. UV printing uses ultraviolet light to cure or dry ink, paint or coatings almost instantly. This uses less energy compared traditional drying methods. Additionally, UV-cured inks are free of volatile organic compounds (VOCs), which are harmful to the environment.
Speaking of inks…
Biodegradable inks are kinder to the environment as they produce less greenhouse gasses than petroleum-based inks. According to EcoEncolse, algae-based ink is the top choice, which uses a carbon-negative algae-derived pigment to colour the ink. Available in both soy and water-based formulations, algae-based ink can be used across a wide variety of printing methods.
Digitalisation
Whilst traditional printing methods have undergone vast developments in waste minimisation and management recently, the rise of the digital printing industry has uplifted sustainable production advances. Digital printing enhances sustainability through machine design and printing technique.
One of the ways we are becoming greener is through inkjet printing and laser technology. Rather than using traditional printing, this prints directly onto the surface of the material, eliminating the use of costly and unsustainable materials found in traditional printing methods, such as film and plates.
By investing in sustainably designed machinery, we can reduce waste through automatic adjusting the size of the paper based on the printing job requirements.
Conclusion
As sustainability continues to permeate business initiatives, innovative methods pave the way to a greener printing industry. Whilst tried and tested transferrable methods such as the Three Rs (Reduce, Reuse, Recycle) continue to prevail, new and emerging technological developments expand horizons for ethical practice within the print industry.
This week has seen groundbreaking developments in 3D printing by ex-SpaceX engineers, revolutionising printing production methods, as reported by TechCrunch. While this development is still in its infancy, the capabilities of commercial printing businesses continue to expand and adapt to new technologies, offering increasingly diverse and innovative solutions.
What is Commercial Printing?
Commercial printing refers to printing services tailored for businesses. It typically involves on-demand and custom printing, as well as large-scale and advanced printing techniques using specialised machinery. The type of product required depends on the industry and business type, but there are some common services that apply across many businesses.
Common types of commercial printing that we’re going to look at are:
indoor and outdoor signs, point-of-sale displays, window graphics.
3. Material Printing
glass, acrylic, metal and more.
4. Stationery
letterheads, business cards, envelopes, brochures and catalogues.
Large Format Printing
If your business needs large items like banners, trade show displays, or promotional prints, you’ll likely need large format commercial printing services. You might hear the terms “large format printing” and “wide format printing” used interchangeably. These terms are both used to describe print projects larger than 18 inches, but there are subtle distinctions between the two:
Wide format printing typically refers to projects between 18 inches and 100 inches, such as banners, retail displays, interior posters, and vehicle wraps. Alternatively, large-format printing describes prints exceeding 100 inches, including wall graphics, scaffolding wraps, architectural murals, and enormous billboards.
The type of machine required for these projects depends on the material being printed. For designs on paper, plastic film or vinyl, a roll-to-roll printer is used. However, printing on display card, foamex, correx, glass, acrylic, ceramic tiles or wood requires a flatbed printer.
Signage Printing
Signage printing is widely used for both indoor and outdoor advertising, helping businesses grab attention, communicate effectively, and boost brand visibility. It encompasses a variety of formats, from large-scale outdoor signs to smaller retail point-of-sale displays.
For example, Cornelius Design to Print partners with Unisan to produce the graphics on their bins, seen in stores worldwide, including top brands like Primark and NatWest. Signage printing often involves comprehensive design services to ensure that the final output meets both aesthetic and practical requirements.
Material Printing
Commercial printing utilises a wide array of materials. Paper printing, involves a range of paper types like glossy, matte, textured, or recycled paper. This option is commonly seen in brochures, posters, business cards, and stationery, and can accommodate various finishes and coatings. On the other hand, cardboard printing is ideal for packaging, such as boxes or point-of-sale displays, as it is durable and rigid. Vinyl printing, known for its flexibility and weather resistance, is perfect for banners, vehicle wraps, and outdoor signage.
Other materials like plastic, fabric, metal, and glass serve more specialised purposes. Plastic printing is used mostly for long-lasting items like membership cards, product labels, and exhibition displays. Fabric printing applies to textiles for promotional items like T-shirts or tote bags, typically within retail and fashion. Metal printing on aluminium or steel sheets is ideal for industrial nameplates or outdoor signs due to its durability. Glass printing is often used for decorative or architectural elements like window graphics or glassware. As mentioned earlier, printing and engraving on Metal using 3D printing on a large scale is an exciting area of ongoing development – watch this space.
Additional specialised materials include wood and ceramic. Wood printing and engraving are commonly used for bespoke signage and display boards that offer a natural aesthetic. For projects using wood, we typically use our Zund CNC Machine. Each of these materials has its own printing process and techniques, tailored to the substrate’s properties and the desired durability or aesthetic finish.
Stationery
Business stationery doesn’t have to stop at a branded pen. While a notebook and pen combo is a popular choice for many business owners, the possibilities extend far beyond this. Commercial printing for business stationery encompasses a wide range of materials used for communication, branding, and professional presentation.
Business cards, letterheads, envelopes, and notepads, are all typically printed on high-quality paper or cardstock to reflect a company’s brand. Business cards, for instance, often feature premium finishes like embossing or foil stamping to leave a lasting impression. Letterheads and envelopes ensure consistency in formal correspondence, reinforcing the brand across all touch points.
Additional items such as presentation folders, labels, and stickers are useful for enhancing brand visibility and ensuring a cohesive, professional appearance.
Commercial printing offers limitless options. As the industry keeps evolving, there’s always a fresh way to get your brand out there.
Not sure where to start? Shoot us a message, we’ll be happy to guide you in the right direction.
Hi, I’m Georgia. I’m the Marketing and Communications Manager at Cornelius Design to Print, and our sister company, Cornelius Electronics. I look after all things strategy, SEO, socials and content creation!
We’re thrilled to announce that Cornelius Design to Print has renewed its partnership with Cardiff City FC for the 2024/25 season. Our first event of the season kicked off last week at the Cardiff City vs. Millwall game. Thanks to the Bluebirds’ performance, we celebrated both a win on the pitch and a great opportunity to connect with the community.
As a longstanding supporters of Cardiff City at Cornelius Design to Print, friendly rivalry runs in our veins. Especially with our sister company, Cornelius Electronics, whose team allegiance lies with Swansea City.
Based in Bridgend, South Wales, we’ve been delivering industrial, technical, and bespoke print solutions for over 20 years. Speaking on the partnership, a spokesperson from Cornelius Design to Print commented:
“We’re honoured to support our local team and to be part of a partnership that enables us to contribute to their success.”
This partnership renewal is part of a broader initiative that includes several regional businesses. Each business collaborates with Cardiff City FC, building long-term brand visibility. According to Cardiff City FC, these partnerships encourage local businesses to seize the opportunity to grow alongside the club, by offering features on stadium TV and StatTV during matches. This means that during national matches, the audience expands to tens of thousands of viewers and football fans.
Cardiff City FC emphasised the importance of collaboration, stating:
“Over many years of playing in the Premier League and Championship, the Club has remained committed to its important role in its local community. Through our collaboration and the introduction of the new Community Partner programme, we will be able to extend support for the people and economy around us even further.”
Eleven Sports Media use transformative technology revolutionise community in sport, as a global leader in community-focused sports partnerships.
Firmly established in football, they’ve crafted partnership programmes across top leagues such as the Premier League and NFL. As a platform for growth, Eleven Sports Media have connected communities across the globe – from iconic venues like London Stadium to Yankee Stadium.
This is our third year of collaboration with Eleven Sports Media and Cardiff City FC. We are excited to see the growth of our partnership throughout the season.
Hi, I’m Georgia. I’m the Marketing and Communications Manager at Cornelius Design to Print, and our sister company, Cornelius Electronics. I look after all things strategy, SEO, socials and content creation!
A folded tray sign is a cost-effective alternative to flat signs, featuring a folded element to form a 3D shape. It’s made by folding the edges of a flat material to create a tray, which adds depth and conceals fixings for a seamless appearance. This provides a diversification of the flat sign with no visible fixings, adding dimension and providing extra protection. These signs are also customisable, with options like illumination, offering versatility in both design and function.
What are they made from?
Folded tray signs are commonly made from aluminium composite material (ACM), also known as dibond. It is ideal for outdoor use, as it is a lightweight and weather-resistant material. Depending on the requirements of the sign, other materials such as aluminium, stainless steel, or acrylic (Perspex) can also be used.
What are they used for?
In any case, folded tray signs can be used for a range of purposes, including shopfront signage, branding, and large outdoor displays. They offer a more polished look than flat signs and can be customised for various appearances, such as incorporating lighting for increased visibility. Suitable for both indoor and outdoor use, they are durable and withstand harsh weather. For instance, Aluminium trays can last over 25 years when properly maintained.
How Do I Make a Folded Tray Sign?
If you’re looking for a step-by-step video guide, check out our YouTube channel for a descriptive tutorial on how to make a tray sign. For a written, in depth guide, read on!
Step 1: Choose Your Material
Choosing the right material depends on a variety of contributing factors. Consider budget, design, location, and expected durability:
Budget-Friendly Option
Aluminium Composite Material (ACM) is an excellent choice for those seeking durability at a lower cost. It’s waterproof, lightweight, and ideal for printing or vinyl wrapping. Its malleability enhances its uniqueness as a budget-friendly material.
Lightweight and weather-resistant
Recyclable aluminium and plastic core
Reduced production costs due to hand-folding
Sign Maker’s Choice
For a high-impact, long-lasting option, aluminium is recommended. Aluminium tray signs are durable and suitable for architectural and retail signage. Given that the encompassing vinyl wrap is occasionally maintained, repaired or replaced, an aluminium folded tray sign can last up to 25 years.
High-impact and professional
Durable, long-lasting material
Requires machine bending, which can increase costs
Illuminated Tray Signs
To achieve an elevated design, consider illuminated folded tray signs with LED fittings. These signs offer internal lighting and are perfect for increasing brand visibility.
Bright, even illumination
Requires professional installation for electrical components
Aluminium tray ensures longevity
Step 2: Cutting and Routing
The next step in the process involves cutting your chosen material to size.
Tools Required:
A CNC router or panel saw is best for clean, precise cuts.
A Zund CNC router can contour the material and create the necessary folds.
It’s important to measure the dimensions, ensuring that you account for the depth of the folds. Clearly mark your lines and cut slowly to avoid complications during folding. Consequently, this will help to eradicate mistakes and smooth edges.
The video above shows our reliable Zund CNC router, to which we entrust this part of the production process.
By automating the cutting process with the G3 Digital CNC Cutter, we can significantly reduce lead times and enhance product quality, ensuring that our products meet our promise of the highest standards.
Step 3: Folding the edges
After cutting, the next step is to prepare the material for folding.
The router should only cut through the top layer of aluminium and part of the core, leaving the outer layer intact to ensure a crisp fold. Gently fold the scored edges by hand or with a bending tool. Apply even pressure to ensure consistent folds across the tray.
Folding by Hand
Start by placing the scored sheet flat on a sturdy work surface. Begin folding one edge upwards along the score line, applying even pressure across the entire length of the fold in a gradual manner. Work on one side at a time, repeating this process for all four edges of the tray.
Maintaining a 90-Degree Angle
The folds must be made at consistent 90-degree angles to ensure the tray maintains its box-like shape. You can use a square tool to check the angle as you fold each side.
Avoid Over-Bending
Be cautious not to over-bend the material, as this can weaken the aluminium or cause stress points that might compromise the sign’s durability.
Step 4: Securing the Tray with Brackets
Next, it’s time to hold the tray in shape. You can use aluminium brackets or rivets to secure the corners in place.
Aligning the Edges
Before placing in the brackets, ensure all corners are perfectly aligned at 90-degrees. Use clamps to hold the edges in place during the securing process. Check that the folds are tight and that the tray retains its proper shape.
Step 5: Riveting
Riveting is a simple process that joins material semi-permanently. It involves drilling holes through the material, inserting rivets, and securing them to hold the tray’s corners firmly in place.
Drilling and Riveting
Properly align the tray’s corners at 90-degree angles to ensure you drill in the correct place. Carefully drill small holes through both layers of the folded aluminium at the corners. Insert rivets through these holes and use a rivet gun to pull the mandrel, expanding the rivet and securing the corners. Typically, two rivets per corner will provide sufficient stability, creating a strong bond without the need for welding, and maintaining the tray’s shape.
Step 6: Finishing Touches
After folding, smooth and seal any rough edges with edge trims for a professional finish.
To protect and prolong the life of the sign, you should apply a layer of protective paint. This will shield the surface from UV damage, moisture, and dirt. For additional protection, you can powder-coat the aluminium. Over and above protection, this will enhance the appearance of your folded tray sign and provide extra resistance to the elements.
Step 7: Installing the Tray Sign
There are a few options depending on the size and location of the sign:
Wall Mounting
For wall-mounted signs, use a hidden fixing system to attach the tray securely. Ensure the wall is strong enough to support the weight and use appropriate fixings.
Post or Frame Mounting
For larger or freestanding signs, the tray may need to be mounted onto posts or within a frame. A structural engineer might be needed to ensure the frame can handle wind loads and other environmental factors.
Looking for a custom tray sign or need a hand with your new project? Contact us today to get started!
Hi, I’m Georgia. I’m the Marketing and Communications Manager at Cornelius Design to Print, and our sister company, Cornelius Electronics. I look after all things strategy, SEO, socials and content creation!
