The Beginner’s Guide to Pad Printing: How It Works & What You Need to Get Started

Pad printing is a surprisingly powerful and versatile printing technology that often flies under the radar—but it's the go-to solution for decorating products that other methods simply can’t handle. From textured, curved, and recessed surfaces to ultra-small or unusually shaped parts, pad printing excels where screen printing, digital, or heat transfer methods fall short. This unique process has become an essential part of production lines across industries such as automotive, medical device manufacturing, promotional products, and consumer electronics, thanks to its ability to produce high-resolution, consistent images on materials like plastics, metals, glass, ceramics, silicone and rubber.

If you’ve ever wondered how logos appear perfectly on golf balls, medical syringes, or keyboard keys, chances are it was done with pad printing. Whether you're completely new to the process or just looking to sharpen your understanding, this comprehensive beginner’s guide will walk you through the fundamentals—how it works, what equipment is needed, and common pitfalls to avoid—so you can feel confident in getting started or expanding your in-house printing capabilities.

Pad printing is an indirect offset printing process where a silicone pad transfers ink from an etched plate (called a cliché) to a 3D part. It excels at printing on surfaces that are:

• Curved or textured
• Small or hard to access
• Made of difficult substrates (e.g., polypropylene, glass, or rubber)

Unlike screen printing or digital printing, pad printing can conform to irregular shapes while maintaining crisp image quality — which is why it's often used to print on objects like:

• Medical syringes
• Golf balls
• Bottle caps
• Keyboards
• Plastic housings
• Promotional items

1. Ink is deposited into a sealed ink cup or open inkwell, which sits on top of the cliché — a steel or polymer plate with an etched image.
2. The ink fills the etched area in the pad printing plate (cliché).
3. A silicone pad presses down onto the pad printing plate (cliché), picking up the ink from the etched image.
4. The pad then moves and presses down onto the part, transferring the image in a controlled and uniform way.

Solvent-based inks quickly become tacky due to partial evaporation, allowing them to release cleanly from the pad and bond effectively to the substrate.

• Pad Printing Machine: The mechanical system that moves the pad and controls the print cycle. Available in pneumatic, electric, or servo-driven configurations.
• Cliché (Printing Plate): Etched with the artwork, available in steel or polymer. Steel clichés last longer, while polymer plates are more cost-effective for short runs.
• Silicone Pad: Comes in various shapes, sizes, and durometers. The shape of the pad affects image distortion and ink transfer.
• Ink & Solvents: Pad printing inks are typically solvent-based and often require hardeners or additives for specialty applications.
• Ink Cup or Inkwell System: Delivers and doctors the ink across the cliché. Most modern systems use sealed ink cups to reduce solvent loss.
• Fixture or Part Holder: Custom-designed to hold the product in place during the print cycle for accurate, repeatable results.

• Pad printing is extremely versatile and works on a wide range of materials:
  • Plastics: ABS, PC, PP, PE, nylon, and more
  • Glass and Ceramics
  • Metal components
  • Rubber and TPE
  • Coated or painted surfaces

  Some materials may require surface treatment (such as flame, corona, or plasma treatment) to improve ink adhesion.

• ✔️ Prints on complex shapes that are impossible for other methods
• ✔️ High-resolution fine-line printing
• ✔️ Fast cycle times for high-volume production
• ✔️ Durable images for demanding industrial applications
• ✔️ Cost-effective for small and medium-sized runs

• Using the wrong ink for your material
  → Solution: Work with your ink supplier to match ink chemistry to the substrate (e.g., Printcolor Series 786 for plastics, Printcolor 792 for elastomers).
• Not thinning the ink properly
  → Solution: Add thinner every 45–60 minutes to maintain viscosity; monitor evaporation in warm environments.
• Incorrect pad shape or durometer
  → Solution: Test different pad geometries for better release and less distortion on curved parts.
• Over- or under-etching your cliché
  → Solution: Match etch depth to your ink and pad — typically 20–30 microns is ideal for most applications.

• Start with polymer pad printing plates (clichés) and basic round pads for flexibility in setup.
• Maintain a clean print area — contamination affects adhesion.
• Invest in a few different pad shapes and sizes to accommodate different parts.
• If printing on low-energy plastics (like PP or PE), consider surface treatment and 2-component inks with hardener.

• At Deco Technology Group, we’ve helped companies across North America set up and scale successful pad printing operations. Whether you're printing promotional items or medical components, we offer:
  • Swiss-made pad printing machines and accessories
  • Printcolor inks engineered for industrial performance
  • Technical support and troubleshooting from industry experts

• 📞 Call us at (714) 639-3326
  📧 Email: sales@decotechgroup.com
  🌐 Visit: www.decotechgroup.com/pad-printing