Quality optimization of inkjet-printed PVC cards via plasma corona, UV radiation and belt speed parameters

Abstract

The production of inkjet-printed PVC cards often faces technical challenges such as ink smearing, low chemical resistance, and poor adhesion. This study aims to optimize the printing quality by analyzing the influence of three independent variables: Plasma Corona treatment, UV radiation, and belt speed variations. An experimental method was employed using eight variations of these parameters on an AMX-UVD-20 Drop on Demand (DOD) inkjet printing machine. The printing quality was comprehensively evaluated through immediate visual morphology observation and dimensional measurements on the day of printing, followed by delayed adhesion stability assessments and solvent resistance tests conducted one month post-printing. The immediate testing revealed that all variations strictly maintained dimensional stability within the ISO/IEC 7810 ID-1 standard, though samples processed at a lower belt speed of 25.5 cm/s combined with integrated Plasma Corona and active UV radiation yielded the sharpest ink morphology with zero smearing. Furthermore, the one-month post-printing evaluation indicated that while all samples eventually established strong physical adhesion due to long-term natural atmospheric curing, configurations omitting active UV radiation completely failed the solvent resistance tests (0 cycles). These findings suggest that while long-term ambient aging can eventually secure superficial substrate bonding, the synchronized combination of Plasma Corona and immediate UV curing is essential for ensuring robust chemical durability and meeting high-speed industrial manufacturing standards