What Are the Limitations of Pad Printing?

Pad printing is one of the most adaptable and widely used printing processes in industrial, promotional, and medical markets. While it excels at printing on uneven and 3D surfaces, there are a few limitations that should be understood when specifying this process for your product.

Pad printing is best suited for small to medium-sized graphics. The image size is typically limited by:

• The size of the silicone pad
• The dimensions of the cliché (printing plate)
• The ink cup diameter (often maxes out at 130–160mm)

This makes pad printing less effective for large-format artwork or oversized products unless custom automation or multiple passes are used.

While multi-color pad printing is common, maintaining tight registration between colors can be more difficult than in digital or screen printing:

• Each color requires a separate cliché and printing cycle
• Slight shifts in part positioning can affect alignment
• Complex color graphics may require advanced automation

Swiss-made microPrint systems (available from Deco Tech) can help minimize these issues with servo-driven accuracy and programmable alignment systems.

Pad printing is typically used for solid spot colors and logos—not photographic images or gradients. This makes it less suitable for projects requiring:

• Full CMYK images
• Subtle shading or halftone transitions
• High-resolution photo reproduction

However, sharp logos, icons, barcodes, and part numbers print beautifully with the right pad, ink, and pressure settings.

Some plastics like silicone, acetal (Delrin), or untreated polypropylene (PP) have low surface energy, making ink adhesion difficult. Without proper surface treatment (flame, corona, or plasma), prints may scratch off or fail adhesion tests.

At Deco Tech, we offer pre-treatment services and testing to maximize ink bonding on hard-to-print materials.

Although pad printing works well on 3D shapes, there are still restrictions:

• Deep recesses or extreme undercuts may block the pad’s contact
• Sharp corners or deep grooves can cause ink distortion
• Excessive curvature can overstretch or wrinkle the image

In such cases, a custom pad shape or alternate method like screen or digital printing may be more appropriate.

Pad printing inks—especially 2-component or UV-curable types—may require:

• Precise mixing and pot life control
• Oven drying or UV curing units
• Environmental controls to prevent dust or humidity issues

We provide guidance on proper ink handling and curing options for production consistency.

You may want to consider screen or digital printing instead of pad printing when:

• The part is very large or flat
• Full-color images are needed
• Fast artwork changes are required without cliché making
• Ultra-high-volume jobs need fewer setup steps

Call 714-639-DECO or email sales@decotechgroup.com to speak with a printing expert and discuss your application needs.