Development of a New Printing Method Using Soft Material Tools

A new printing method for metal using soft material tools has been developed. This method uses paper or plastic film with a fine pattern produced by the laser printer as a printing tool. The aluminum disc is compressed with a soft material tool between the upper and lower flat dies. In order to print with high accuracy with a uniformed pattern onto a metal surface, the effects of the process conditions on printing have been investigated. Experimental results using the soft material tools showed that the good condition for high accuracy was changed by the combination of the average pressure and the workpiece shape. The new printing method can print patterns easily onto the metal workpiece. The pattern can be observed from each workpiece surface. When using paper, the surface profiles of the workpiece are not clear because the printed pattern is hidden by the surface roughness of the paper. When using the PET film, the surface pattern can be clearly observed. The average pressure is needed to print the pattern clearly and uniformly. When decreasing the diameter and thickness ratio D/t of the workpiece, the required average pressure is decreased.