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On a crisp February morning in 2025, digital embellishment designers from around the world gathered virtually for a masterclass led by Matthew Redbear, an expert in the field of digital foil design. As attendees logged in, the excitement was palpable – this was an opportunity to learn from one of the best in the industry.
Matthew began by demystifying the digital foil process, explaining how it differs from traditional foiling methods. He painted a vivid picture of the two-step process: first, laying down an inkjet varnish, typically at 72 microns thick, and then applying foil that adheres only to the varnished areas. This technique, he explained, allows for a raised effect without the need for additional embossing or counter dies, setting it apart from traditional methods.
As Matthew delved deeper into the intricacies of digital foil, he addressed one of the most common questions in the industry: where to source foil for digital embellishment presses. He shared his experiences with various manufacturers, from Kurz and Liberty Foils to Great Western Foils and Crown Roll Leaf. Matthew emphasized that each print shop often develops a preference based on their specific machine characteristics and substrate choices.
The masterclass took an interesting turn when Kevin Abergel, another industry expert, chimed in with a question about the relationship between foil price and quality. Matthew's response was enlightening – he had observed no direct correlation. In fact, he shared an anecdote about finding a less expensive foil that outperformed pricier options, highlighting the importance of testing and experimentation in the field.
As the session progressed, Matthew shared best practices for file preparation, stressing the importance of proper resolution and layer organization. He recounted a personal experience of revolutionizing a print shop's workflow by demonstrating how to properly prepare files, much to the amazement of the staff. This anecdote underscored the importance of proper file setup in achieving optimal results with digital foil.
The conversation then shifted to design considerations, with Matthew offering valuable insights on avoiding common pitfalls like plugging and tracking issues. He shared tips on minimum line widths and mask density, drawing from his extensive experience in the field. Matthew emphasized the importance of understanding the limitations of the technology, particularly when working with fine details or intricate patterns.
One of the most exciting parts of the masterclass came when Matthew and Kevin discussed innovative techniques. They explored the possibilities of foil on foil, aqueous overcoats, and varnish overlays. Matthew's enthusiasm was contagious as he described the "otherworldly" look achieved by applying an aqueous overcoat over foil – a technique that, in his words, "doesn't look like anything else out there." This discussion opened up new creative avenues for the attendees, encouraging them to push the boundaries of what's possible with digital foil.
As the session neared its end, Matthew turned his attention to the future of digital foil embellishment. He passionately argued that packaging was the next frontier for this technology, particularly in industries like CBD, cigars, and fitness supplements. To illustrate his point, he shared several examples of packaging designs, each showcasing the unique possibilities of digital foil. The attendees were captivated by the potential applications in these growing markets.
The masterclass concluded with a lively discussion about experimenting with textures and patterns. Kevin shared his experiences with creating concave and convex effects using varnish patterns on foil, while Matthew introduced the concept of lenticular patterning, encouraging attendees to explore these techniques in their own work. This final segment of the class sparked a flurry of creative ideas among the participants, with many eager to try out these advanced techniques in their own projects.
Throughout the session, Matthew emphasized the importance of understanding the unique characteristics of each machine and substrate. He shared anecdotes of troubleshooting issues in various print shops, highlighting how factors like foil age, machine calibration, and even environmental conditions can affect the final result. These real-world examples provided invaluable insights for the attendees, helping them anticipate and overcome potential challenges in their own work.
The masterclass also touched on the sustainability aspects of digital foil embellishment. Matthew discussed how some foil manufacturers are focusing on developing more environmentally friendly options, catering to the growing demand for sustainable packaging solutions. This segment of the discussion resonated strongly with many attendees, who were keen to explore ways to reduce the environmental impact of their design and production processes.
As the virtual meeting came to a close, attendees left with a wealth of new knowledge and inspiration. Matthew's passion for digital foil design had shone through, leaving everyone eager to apply these techniques in their own projects. The masterclass had not just been a lesson in technique, but a glimpse into the future of digital embellishment – a future that promised to be as bright and shimmering as the foils they had discussed.
As the dust settled, Matthew reflected on the session with satisfaction. He had not only shared his knowledge but had also learned from the experiences and questions of the attendees. The masterclass had reinforced his belief in the power of collaboration and continuous learning in pushing the boundaries of digital foil design. With renewed enthusiasm, he began planning for future sessions, eager to continue guiding the next generation of designers in this exciting and ever-evolving field.
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