Diving Into the Digital Embellishment Bucket? Be sure to bring a snorkel...

Indulge me while I reminisce like an “old timer.”

In June of 2022, the print industry saw APTech and the Foil & Specialty Effects Association (FSEA) introduce Amplify, the first finishing, packaging, and design event specifically created for the post-press embellishment industry. This three-day event brought together key players in the print finishing value chain, from designers and creative agencies to specialty effects technicians, print finishers/OEM’s, consultants, and more.

It was time — not only to highlight advancements in digital technology being applied to what was traditionally a specialty analog market — but also to begin to standardize the vocabulary and thought processes behind how it all fits together. Digitally applying foils and varnish highlights to various substrates now requires a host of supporting processes. Equipment manufacturers are constantly revising their tech. Designers and creators are forever lost in the whirlwind of what is possible and what is not. How do we sort it out?

For starters, let’s go ahead and dive into the “bucket.”  What do we mean when we say digital embellishment?

Digital methods can include: adding foil, varnish overlays, and special cut shapes and engraving, just to name a few.  Generally, it’s replacing analog coating and decoration by converting those processes with digitally-driven methods that are proven to be more cost-efficient and greener for the environment. Production times are hastened, set-up cost and materials are reduced or eliminated, and lower-volume quantities are now feasibly possible. Imagine having the advantage of making only one or two prototypes to live-proof to your customer prior to full production. Gone are the days of trying to imagine what the finished piece might look like. 

One main distinction was emphasized at Amplify 2022 for clarity. Foil overlay embellishments are split into two categories: Digital, and Polymer. Digital refers to the more rudimentary “sleeking” method that uses rich-black toner as the capture for the foil overlay. Polymer uses an inkjet varnish as the base capture for the foil overlay, providing either a traditional flat look or a raised “tactile” effect depending on how much varnish is used underneath.

As much as the digital influence helps to simplify and streamline the process, it also brings more variables into the equation. Some paper stocks work well, others don’t. Handling, cutting, creasing and folding also require the transition to digital, such as flat table cutters to prevent compressing the fragile raised varnish and foil overlays. On the front end, designers need to optimize their file building skills to correctly build (and name) layers and swatches that will route properly when the PDF file is ripped for output. But is any of this different than the challenges of every prepress department throughout all of history? Probably not… it’s just different, with more technology and variables involved.

What about compatibility with different commercial print presses? The press sheet might be printed on an HP Indigo, Xerox Iridesse or iGen. Some inkjet printers use aqueous inks and others are UV, such as the Konica Minolta KM-1. And then there’s traditional offset using an aqueous flood coater. All these are compatible with digital embellishments methods, but each one requires uniquely different setup parameters and handling. Print finishing shops see a variety of input, for which they must produce a consistent output. Tools such as pre-coating the paper stock and corona treatment can help to level the playing field — but in the end — the greatest asset is operator experience while using best practices, and also knowing when to bend the rules a little to get the required results.

But, we all know this transition to excellence takes time, effort, collaboration and learning.  Fortunately, front end designers/prepress and machine operators have more resources available to them than ever before. 

For example, Taktiful hosts events and monthly virtual meetups, publishes software, produces podcasts, publishes case studies, and has recently announced Taktical Masterclass Trainings. The Foil and Specialty Effects Association hosts virtual meetups and exhibits such as the upcoming AMPLIFY 2025 being held at the Donald E. Stephens convention center in Rosemont, IL (near O’Hare, Chicago area) June 10-12, 2025. PaperSpecs presents glorious events such as PaperSpecs Live and hosts the UNBOXED online webinars to empower curious designers with techniques and know-how (be sure to join the wait list to be notified of upcoming events). 

So go ahead and dive into the digital embellishment bucket. There’s plenty of support. You might not need that snorkel, after all.