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Doctor Blade Description:

Metal Industrial has prioritized meeting customer needs for many years by continuously adding new features to their ink doctor blade. Our blades are used in gravure packaging, flexographic printing, UV flexo, offset varnishing, decorative materials printing, pressure-sensitive printing, screen printing, and coating applications.

Metal Industrial menggunakan jalur produksi CNC presisi untuk memproduksi bilah pencampur tinta berkualitas tinggi. Proses produksi dan pemeriksaan ketat kami memastikan produk kami menonjol dalam industri bilah pencampur tinta.

Dengan mematuhi standar kualitas yang utama dan berfokus pada persyaratan pelanggan, Metal Industrial memungkinkan klien untuk mempertahankan kualitas cetak yang konsisten dalam proses cetak yang panjang dan meminimalkan waktu henti.

Pisau ink doctor kami cocok untuk pencetakan gravure dan fleksografi. Masalah seperti rona warna, goresan, filamen, garis, dan keausan lapisan krom biasanya muncul karena beragamnya mesin cetak dan bahan substrat. Metal Industrial menawarkan berbagai pisau untuk mengatasi berbagai kebutuhan ini. Untuk pencetakan kemasan gravure, tinta yang lebih kental sering kali menyebabkan goresan dan keausan ekstra pada pisau dan silinder. Pisau kami beradaptasi dengan tinta ini dan dapat digunakan kembali, sehingga mengurangi waktu henti.

Percetakan fleksografi:

Bilah keramik Metal Industrial ideal untuk proses pelapisan dan laminasi dalam pencetakan fleksografi. Mesin cetak flekso modern biasanya menggunakan rol aniloks dan bilah doktor untuk pemindahan tinta. Lebar cetak mesin cetak flekso berkisar antara 200 mm hingga 4000 mm. Sistem bilah tunggal berfungsi untuk mesin cetak yang lebih kecil, sedangkan sistem tertutup lebih baik untuk mesin cetak sedang hingga besar. Kecepatan cetak berkisar antara 50 hingga 450 meter per menit. Bilah terbalik biasanya memiliki sudut 30°-40°. Karena permukaan rol aniloks keramik yang halus, tekanan bilah seharusnya minimal. Faktor yang memengaruhi masa pakai bilah meliputi bentuk dan jumlah garis sel aniloks serta ketebalan bilah.

Mata pisau keramik Metal Industrial sesuai untuk pencetakan fleksografi, dengan mata pisau setebal 0,20 mm dan terkadang 0,15 mm. Sistem tertutup tidak memerlukan mata pisau cadangan, jadi mata pisau standar, miring, dan komposit semuanya dapat digunakan.

Pencetakan Halftone:

Untuk pencetakan halftone, seperti pencetakan label, ketebalan bilah biasanya 0,075 mm. Prinsip umumnya adalah bilah yang lebih tipis memiliki kinerja yang lebih baik.

Fitur Produk:

• Halus, lurus, dan siap pakai tanpa diasah
• Cocok untuk sistem scraper maju, mundur, dan tertutup
• Mengurangi waktu henti

Spesifikasi:

• Lebar: 8-80mm
• Ketebalan: 0,15-0,5mm
• Tinggi ujung bilah: 1,3-1,5 mm
• Ketebalan tepi bilah: 0,075mm
• Kekerasan: 580HV
• Toleransi kelurusan: 0,1/3000mm
• Pengemasan: 100m, 200m, atau kustom

Persyaratan Pemasangan: Untuk pencetakan gravure, sudut kontak ideal untuk pemasangan bilah adalah 55-65°. Sudut yang lebih kecil dapat mengakibatkan pengelapan tidak tuntas dan pelat berembun.

What do Doctor Blade Mean?

A doctor blade is a thin, flexible blade, typically made of metal or plastic, used in various industrial coating and printing processes to control the thickness of a liquid film applied to a surface. In printing, particularly flexography and gravure, the doctor blade plays a crucial role in removing excess ink from the surface of the printing cylinder (anilox roll or gravure cylinder), ensuring that only the ink held within the engraved cells is transferred to the substrate. The term “doctor blade” originates from its function of “wiping off” or controlling the amount of liquid.

Beyond printing, doctor blades are also used in other coating applications to meter or level the thickness of coatings applied to various substrates.

Uses and Applications of Doctor Blades

Doctor blades have diverse applications across several industries:

• Flexographic and Gravure Printing: This is one of the primary applications, where the doctor blade ensures a consistent and controlled amount of ink is transferred to the printing plate or substrate by removing excess ink from the anilox or gravure cylinder. This is crucial for print quality, color consistency, and preventing issues like flooding or smearing. They are used in various printing applications, including packaging, labels, newspapers, and flexible materials.
• Proses Pelapisan: Doctor blades are used in various coating methods to apply thin films of liquids onto substrates. This includes:
  • Doctor Blade Coating: A method used to create thin films on large surfaces, controlling the thickness of the applied solution. Applications include manufacturing of electronics, solar cells, and specialized coatings.
  • Paper and Board Machines: Doctor blades are used to scrape off foreign material that accumulates on rolls, ensuring web quality and preventing damage to soft rolls. They also redirect the web to prevent wrapping around rolls.
  • Textile Coating: Applying coatings to fabrics for various properties like waterproofing or durability.
  • Adhesive Coating: Applying even layers of adhesive onto tapes and labels.
• Pembersihan: In some industrial machinery, doctor blades are used to clean rollers and remove debris or excess material.

Common Materials for Doctor Blades

The selection of material for doctor blades is critical and depends on the specific application, the material being processed (ink, coating solution), the substrate, and the speed of operation. Common materials include:

• Metal Blades:
  • Baja karbon: Economical and offers good initial sharpness. Different grades like bright and blue carbon steel are available.
  • Stainless Steel: Offers better corrosion resistance, especially with water-based inks.
  • Perkakas Baja: Provides enhanced wear resistance for longer blade life, particularly with abrasive inks or coatings.
  • Bronze: Used in some applications.
  • Coated Steel: Steel blades can be coated with materials like ceramics or carbide to increase wear resistance and reduce friction.
• Plastic Blades: Offer good durability and can last longer than steel in some applications. They are often self-lubricating and resistant to mechanical wear and abrasive chemistries like high titanium white inks and special effects coatings. Examples include:
  • Polyethylene: Good for soft rolls and when lubricated.
  • Polyester:
  • UHMW (Ultra-High Molecular Weight Polyethylene):
• Fiberglass and Carbon Fiber Composites: These materials offer improved wear resistance over metal blades, reduce roll scoring, and provide excellent cleaning performance. Carbon fiber blades offer the longest wear life and high flex resistance.
• Abrasive Blades: Used for specific applications like maintaining porosity of rolls or periodic removal of build-up. These can be made with fiberglass and epoxy resin or reinforced with carbon fiber.

Common Doctor Blade Shapes

Doctor blades come in various edge profiles and thicknesses to optimize performance for different applications:

• Straight Edge (Square Edge): A 90-degree edge, often used as a backer blade.
• Beveled Edge: An angled edge (e.g., Standard with a nominal 15° angle, Superhoned® with a 4.5° angle, Superhoned® Plus with a 2.2° angle) that provides a sharp contact point and controlled wiping action. The long bevel of Superhoned® edges helps control tip deflection and contact angle.
• Rounded Edge: Offers a strong, rigid, and polished working edge, suitable for lower screen anilox rolls or abrasive inks.
• Double Cut (Parallel Edge): Features two parallel cutting edges.
• Stepped Edge (Lamella Tip): A specialized profile that can improve wiping efficiency and reduce spitting in flexographic printing.

The thickness of the doctor blade also varies depending on the application and the required flexibility and stiffness. Common thicknesses for metal blades range from 0.004″ to 0.020″ or more.

Working Principle of Doctor Blades

The doctor blade operates by applying controlled pressure against the surface of a rotating cylinder (anilox or gravure) or a substrate being coated.

In printing:

1. Ink is transferred to the engraved cells of the anilox or gravure cylinder as it rotates through the ink fountain or chamber.
2. As the cylinder continues to rotate, excess ink remains on the non-engraved surface (land areas).
3. The doctor blade, held at a specific angle against the cylinder, wipes away this excess surface ink.
4. Only the ink held within the cells is then transferred to the printing plate (flexography) or directly to the substrate (gravure).

In coating:

1. A liquid coating is applied to the substrate.
2. The doctor blade is then drawn across the coated surface at a controlled angle and pressure.
3. The blade removes excess coating, leaving behind a film of a specific and uniform thickness determined by the gap between the blade and the substrate, as well as the blade angle and pressure.

The effectiveness of a doctor blade depends on factors such as the blade material, edge profile, thickness, the angle at which it is held against the cylinder or substrate, the applied pressure, the surface condition of the cylinder or substrate, and the properties of the ink or coating being used. Proper selection, setup, and maintenance of the doctor blade are crucial for achieving optimal results in printing and coating processes.

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Mengapa Memilih Metal?

1. Layanan impor bebas repot satu atap

Mudah menikmati kenyamanan impor, dari transportasi hingga bea cukai, kami menangani seluruh prosesnya, Anda hanya perlu membayar PPN dan menunggu barang tiba di perusahaan.

2. Harga Kompetitif

Kami telah melihat bilahnya digunakan dalam banyak aplikasi dan siap menangani proyek apa pun yang Anda lakukan - memberikan akurasi, daya tahan, dan harga kompetitif yang tak tertandingi.

3. ODM & OEM tersedia

Baik Anda menyediakan gambar, sketsa, atau sampel, kami dapat menggambar dan memproduksi untuk Anda. Kami juga memiliki kemampuan untuk membantu memodifikasi desain dan spesifikasi yang ada untuk meningkatkan hampir semua aplikasi perkakas industri. Silakan hubungi tim penjualan khusus kami untuk mendiskusikan kebutuhan spesifik Anda.

4. Kontrol kualitas

Serangkaian pengujian dan inspeksi dilakukan untuk mengendalikan kualitas, termasuk inspeksi artikel pertama, inspeksi material yang masuk, dan material yang disertifikasi, inspeksi kualitas dalam proses, dan inspeksi kualitas akhir.

5. Pengadaan yang fleksibel, kerjasama tanpa batas

Apakah Anda seorang importir, distributor, grosir atau pengguna akhir, kami mengundang Anda untuk bergabung dengan kami dengan MOQ minimum, tanpa kerumitan untuk bertanya dan lebih banyak kebebasan untuk membeli.

6. Monitor luar negeri, laporan kemajuan produksi secara real-time

Jadilah monitor eksklusif Anda, transmisi rutin setiap simpul penting di jalur produksi, tidak peduli seberapa jauh jaraknya, kemajuan produk sejauh mungkin untuk dipahami!

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