What is Digital Printing?

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Digital printing is a printing method that prints digital files on materials such as paper, canvas, and fabric, using ink or toner using digital printers. This process removes the need for printing plates, resulting in a quicker setup and more adaptable production.

So, how is digital printing different from offset printing?

Offset printing uses metal plates to print images, whereas digital printing works from digital files like PDFs, using software and drivers to convert the file for printing. The output is comparable to offset printing, but the process is simpler and more efficient.

Digital printing is more efficient because it reduces setup time by eliminating the need for designing, creating, and aligning printing plates. It also allows for on-demand printing, meaning smaller runs can be produced without the waste associated with traditional methods.

Changes or corrections to the design are also easier in digital printing.

This article will explain how digital printing works, its types, and the benefits it provides over traditional methods.

How does Digital Printing Work?

The digital printing process begins with the creation of a file, which can include text, images, or both.

Digital files are processed in two different ways before they are printed.

Some files are converted into raster graphics images (bitmaps),
Others, such as vector-based PDFs or EPS files, may remain in their original format.

The file processing depends on the artwork and the capabilities of the digital printer. Popular file formats in digital printing include PDF, TIFF, JPEG, and EPS.

Raster Vs Vector

Raster images use a matrix of pixels while vector graphics use mathematical formulas to represent the image. Raster images cannot be scaled while vector images can (theoretically) be scaled indefinitely.

The process of preparing the file for printing, known as Raster Image Processing (RIPping), involves converting the file (if needed), managing colour separations, adjusting resolution, and ensuring proper alignment. RIP software plays a critical role in controlling how ink or toner is applied to the material.

Once the file is processed, the digital printer uses the data to guide the printing process. There are many digital printing technologies, including laser, inkjet, dye sublimation, and UV printing.

Laser Printers use a laser beam to create an image on a light-sensitive photoreceptor. Toner, a plastic-based powder, is attracted to the areas exposed by the laser. The toner is then transferred onto paper and fused with heat at temperatures around 400°F. The size of toner particles, typically ranging from 5 to 15 microns, impacts the resolution and quality of the print. Laser printers are known for producing sharp, smudge-resistant prints.
Inkjet Printers spray tiny droplets of ink onto the material. Droplet sizes can vary significantly, from as small as 1.5 microns to larger sizes, depending on the printer type and intended application. Inkjet technology is commonly used for high-resolution prints and is adaptable to a wide range of materials, including paper, fabric, and large-format media like posters and banners.
Dye Sublimation involves printing onto a transfer material that is then pressed onto the final surface using heat. The dye transforms from a solid to a gas without becoming liquid (sublimation), bonding with the material. This method is commonly used for textiles and promotional items.
UV Printing uses ultraviolet light to cure ink as it is printed. This allows printing on a wide variety of materials, including plastics, metals, and glass. The instant curing process also makes UV printing ideal for fast production.

Finishing Process

After printing, materials often go through finishing processes such as cutting, folding, laminating, or binding to create the final product. These steps are essential for products like packaging, brochures, and promotional materials.

Types of Digital Printers

Types of Digital Printing	Where They Are Used
Laser Printing	Office reports, invoices, brochures, flyers, high-volume black-and-white documents, and labels. Suitable for corporate settings and printing on thick cardstock.
Inkjet Printing	High-quality photo books, fine art, posters, and vinyl banners. Also used for printing on various materials such as photo paper, canvas, fabric, and synthetics.
Direct-to-Garment (DTG) Printing	Custom t-shirts, hoodies, and boutique clothing, primarily printed on cotton or cotton-blend fabrics. Best for small runs and requires pre-treatment for dark fabrics.
Dye-Sublimation Printing	Custom mugs, mouse pads, sportswear, and promotional products. Only suitable for polyester fabrics and polymer-coated surfaces.
Large Format Printing	Billboards, trade show banners, vehicle wraps, wall murals, floor graphics, and architectural blueprints printed on materials such as vinyl and fabric.

Advantages of Digital Printing

Let’s look at the advantages of digital printing which makes it popular for a wire variety of printing requirements in businesses of all sizes.

Printing Speed: Digital printers are known for their fast output. For instance, the Xerox Versant 4100 reaches speeds of up to 100 pages per minute (ppm), while the HP Indigo 100K can print up to 4,600 duplex sheets per hour, making it ideal for long-run jobs. These high speeds allow for handling both small and large orders efficiently, meeting tight deadlines for high-volume jobs
Resolution and Image Quality: The print quality of digital printers now matches (or even surpasses for high-end printers) traditional offset printing. Digital models often deliver resolutions of 1200 x 1200 dpi, and advanced models, such as the Xerox Iridesse, offer up to 2400 x 2400 dpi. Another high end printer, HP Indigo Digital Presses exceeds the offset quality with its HD Imaging System, delivering 1600 DPI resolution with up to 290 LPI screen sets. This results in vibrant colours, sharp details, and clear text, making digital printing suitable for high-quality marketing materials, photographs, and brochures.
Media Compatibility: Digital printers are highly versatile, accommodating a wide variety of media from standard paper to synthetics, canvas, and fabric. The Xerox Iridesse supports media weights ranging from 52 to 400 gsm, while HP Indigo presses expand capabilities to include speciality substrates like metalised prints, plastic cards, and synthetic products. This versatility makes digital printing ideal for industries that require diverse media applications, such as textile printing or promotional products.
Customisation and Flexibility: One of the standout benefits of digital printing is its ability to produce on-demand and variable data printing (VDP), which allows for easy customisation of each print. HP Indigo presses offer additional customisation with Mosaic’s variable design technology, which automates the creation of millions of unique designs. Specialty inks, such as fluorescent, metallic, and white inks, are also widely available, enabling striking and personalised print applications.
Automation and Workflow Optimization: Modern digital printers have advanced automation features that streamline the entire process. Xerox’s PredictPrint Media Manager and HP Indigo’s PrintOS provide cloud-based management for job submission, colour calibration, and real-time error detection. These tools improve workflow, reduce time to production, and minimise manual involvement. The result? Better accuracy and efficiency compared to offset printing.
Sustainability: Digital printing presses, such as the HP Indigo and Xerox Iridesse, are more energy efficient, making them more sustainable than traditional offset printers. The HP Indigo reduces energy consumption by up to 25% per page while the Xerox Iridesse can reduce energy use by 60% in some high-output environments. In comparison, older offset or liquid toner-based printers can consume 30-50 kWh per day under heavy use.

High Output and Duty Cycle: Digital printing presses are built to handle large workloads. The Xerox Iridesse has a monthly duty cycle of up to 2,250,000 impressions, making it perfect for high-volume commercial printing. HP Indigo presses, with their Enhanced Productivity Mode, can increase throughput by 33% while reducing energy consumption, ensuring businesses can handle large-scale print campaigns without sacrificing quality.

Conclusion

Digital printing has redefined how businesses manage their printing tasks. With its combination of speed, precision, and versatility, it allows for efficient production across a wide range of media with ultra-detailed quality. Whether you need small custom runs or large-scale prints, digital printing meets the demands of today’s fast-paced environments. Its flexibility also reduces waste and streamlines workflows, making it a sustainable choice for modern businesses.

To find the perfect printer for your office or industrial needs, explore the Triton Store at tritonstore.com.au and discover the best selection of thermal printers here.