UV-3D Printing: The Next Generation of ADA Sign Fabrication
By Mike Shabluk | April 25, 2023
Over the years, the way we design and create ADA signage has changed a lot. The introduction of new technology has made sign fabrication faster, easier, and more reliable. And although traditional UV direct printing has been the go-to process in recent years, a new version—UV-3D printing—is taking its place.
If you’re a print or sign shop owner who’s unfamiliar with this method, now’s the time to learn. Once you discover how it works, you’ll see why experts consider it the next generation of ADA sign fabrication. More importantly, you’ll understand how the process can benefit you and your clients!
What Is UV-3D Printing?
UV-3D printing is a process that combines the quick-drying nature of UV printing with the material layering of 3D printing. With this method, a substance such as UV-hardening ink is applied to a material substrate and cured before another layer is applied. Once the final pass is complete, the result is a solid object that’s adhered to the material substrate.
Essentially, this method is a type of layered printing. When used for signage, layers of ink build on one another to create the following:
- Raised text and numbers
- Braille
- Detailed graphics
- Design texture
How Is UV-3D Printing Different from Traditional UV Printing?
As touched on previously, UV-3D printing is basically the latest iteration of UV printing. However, instead of printing a single layer of ink, it prints multiple layers to form an object with greater height, width, and depth. This new method is preferable to traditional UV printing when dimension and texture are required for a project.
The process also differs in what type of equipment is used. Regular UV printing is done with a UV direct printer, whereas the new method can only be done with a specialty printer.
What Equipment and Materials Are Needed for UV-3D Printing Signs?
The equipment and materials needed to perform UV-3D printing aren’t too far off from what’s used in traditional UV printing. That said, there are some notable differences. To apply this method for ADA signage fabrication, the following tools are required:
- Material substrate
As with any sign project, you need to select an appropriate material for the sign itself. The great thing about UV-3D printing is that it can create raised characters, graphics, and other design elements on a variety of surfaces. Typically, ADA signs are made using a durable material such as acrylic or laminate.
- UV-hardening ink
The liquid substance dispensed on the material substrate during printing plays a major role in this process. For sign-making purposes, it’s crucial to have UV-hardening ink that can build up in layers to form the raised elements. Moreover, you need ink that’s compatible with the printer. Fortunately, most printer manufacturers make it easy to get the correct ink for your project. The right one can even provide you with flexible ink for more elastic materials and rigid ink for harder materials.
- Design program
Of course, you also need a design program that lets you create the layout of the sign to meet ADA specifications. However, not all programs will work with this method. That’s why it’s important to have one that allows you to set measurements for 3D elements and is compatible with the printer.
- Specialty printer
For UV-3D printing, you also need a specialty printer. Specifically, you need a UV-LED printer designed to build layers of UV-hardening ink to the appropriate dimensions. It’s worth noting that few printers on the market have the necessary capabilities to print ADA-compliant/braille signage.
The Collaboration between Direct Color Systems and MUTOH
Direct Color Systems (DCS) is a leading manufacturer of small, medium, and large-format UV-LED inkjet printers. More importantly, the company holds a patent for manufacturing direct-to-substrate braille and ADA-compliant signs. Up until last year, only certain DCS printers could be used to produce UV-printed ADA signs reliably. But that changed when the company partnered with MUTOH America, Inc., a leader in wide-format printers, cutters, inks, and accessories.
The collaboration between DCS and MUTOH, which was announced in April of 2022, made it so that MUTOH can also sell their UV-LED printers for ADA/braille printing purposes. Tom Kaplinski, President of DCS, stated:
“This collaboration recognizes the importance of DCS intellectual property relating to technology for producing ADA-compliant Braille signage and enables MUTOH to promote and sell their own line of printing equipment through their distribution channels and to their end-users.”
At Erie Custom Signs, we’re excited to have a new MUTOH XpertJet 661 UF printer in our shop for UV-3D printing ADA signage.
Why Is UV-3D Printing Ideal for ADA Signage?
Just as there are several ways to apply traditional UV printing, there are many ways to apply the new method. However, ADA signage is among the most noteworthy, especially for print and sign shop owners. Creating ADA-complaint signs can be difficult, and doing it incorrectly can lead to negative consequences for you and your client. Fortunately, enlisting the help of a third-party fabricator with UV-3D printing capabilities can ensure a top-quality finished product.
Here’s why this process is perfect for crafting ADA signage…
- It requires less material and equipment than other processes.
UV-3D printing is an additive process (i.e., adding material on top) rather than a subtractive one (i.e., removing material). This means you don’t need additional materials or equipment like you would using photopolymer or Raster® Braille. You can add the braille and all other design elements with a single machine.
- It can be used to print raised elements in a variety of colors.
Applying this process using a specialized DCS or MUTOH printer allows you to print raised characters, graphics, and other elements in a variety of colors. You can even print in white, which not even a lot of regular UV printers can do. As a result, you can offer your clients ADA-compliant signage that fits their color scheme.
- It offers greater damage resistance.
With UV-3D printing, all raised characters and graphics adhere to the material substrate. So, they’re less prone to damage. This is a major benefit to the client, as there’s often a worry that signs will chip, fade, or even be vandalized. However, the use of this method provides superior durability.
- The production time is faster than other methods.
Another advantage of UV-3D printing over other fabrication methods is that it’s significantly faster. Signs can be produced more quickly because there are fewer machines involved and the ink cures instantly. As such, clients who place an order can look forward to a shorter turnaround and avoid the repercussions of having poor (or nonexistent) ADA signs in their building.
- It can ensure ADA compliance.
Finally, printing signs this way with a DCS or MUTOH printer can ensure ADA compliance for end users. These specialty printers make it easy to create elements such as 1/32” raised characters and grade 2 braille. So, you and your clients can feel confident that all ADA guidelines are met.
Takeaway
ADA sign fabrication has evolved significantly over the years, and though UV-3D printing is only the latest process being used, it will be hard to beat. If you’re interested in offering ADA signs to your clients, it’s worth partnering with a third-party fabricator that has the necessary equipment already. Reach out to our team for a quote today!