Designers seeking to add metallic finishes to products or packaging can choose between two methods: cold foil printing and hot foil stamping. Understanding the differences between these techniques helps manufacturers select the best approach for their needs.
Hot foil stamping
Hot foil stamping is an established method with centuries of history. A die uses both heat and pressure to adhere the foil and a heat-activated adhesive to the substrate. This traditional approach has served the industry well but comes with certain limitations — primarily, the cost and lead time of die creation regardless of production volume.
Cold foil printing
Cold foil printing represents newer technology in the decorative printing space. Inkjet print heads jet UV-activated adhesive onto a substrate, and foil is briefly pressed onto the substrate and passed under a UV light. The adhesive cures instantly, with foil remaining only where adhesive was applied.
Why cold foil wins on flexibility
Cold foil printing eliminates tooling costs entirely. Additional benefits include reduced changeover time (simple mouse clicks versus 30 minutes to 8 hours), the ability to apply gradients through drop-on-demand technology, and the option to use cold foil on heat-sensitive substrates. As an inline process, it allows simultaneous application of colors and coatings, reducing storage needs and accelerating product delivery to market.