Print Design Troubleshooting

If you're not checking these before sending your print to the factory… you're risking costly mistakes. 👇 From mismatched Pantones to visible repeat lines, even the smallest oversight can lead to expensive delays or flawed production runs. After 15+ years designing for brands like Paul Smith, Peter Pilotto and Lily & Lionel, I’ve developed a rock-solid checklist that ensures every print file I send is factory-ready, clean, and crystal clear. Here’s my go-to checklist I run through before sending any print file off to the factory — because getting your files factory-ready is one of the most important (and overlooked!) steps in a smooth, cost-effective sampling process. ✅ DPI Check – Always 300 DPI minimum. No one wants pixelated artwork. ✅ Scale Check – Print it out, hold it up to your body. Is it flattering? Too bold? Too small for that dress? ✅ Repeat Size – Does it fit within factory screens (32, 64, 81cm)? Is it appropriate for the garment size? Think maxi dress compared to a bikini. ✅ Seamless Repeat – Zoom in and scan your artwork from top to bottom. Any visible lines or flaws? Now’s your chance to catch them. Check the repeat lines horizontally and vertically. ✅ Print Technique – Is your file formatted correctly? (e.g. indexed for screen print, flat for digital, psd, Tiff?) ✅ Layer Organisation – Label your layers clearly or provide a flat file with unnecessary extras removed. You're factory will thank you for the clarity! ✅ Pantone Colours – Double-check that your colour references match your palette exactly. ✅ Tech Packs – This needs its own post (coming soon!) but make sure your print info is included clearly, i.e. scale, pantone references, printing technique etc. These steps help you avoid costly back-and-forth, save your client time and money — and keep your factory happy! What would you add to this list? Anything here you hadn’t thought of before? 👇 Want the full breakdown? I’ve just put together a free, detailed guide you can download or share with your team. You can get it here https://lnkd.in/eNJvTuEv #PrintDesign #FashionDesignTips #TextileDesigner #SamplingChecklist #FreelanceDesigner #SurfacePatternDesign #FashionProduction #DesignWorkflow

Flexographic printing plate potanial solutions:- Flexographic (flexo) printing plates can face various challenges that affect print quality. Below are some common issues and potential solutions: 1. Plate Lifting or Edge Curling Cause: Poor adhesion to the mounting tape or incorrect tape selection. Solution: Use the correct adhesive tape thickness and type. Ensure the plate and cylinder are clean before mounting. Apply even pressure when mounting to avoid air pockets. 2. Dot Gain or Loss of Fine Details Cause: Excessive pressure, improper plate material, or poor ink transfer. Solution: Use a high-resolution plate with proper surface texture. Adjust the impression pressure to minimize distortion. Use correct anilox roll specifications for better ink control. 3. Ink Spreading or Dirty Printing Cause: Over-impression, incorrect ink viscosity, or worn plates. Solution: Reduce impression settings to avoid excessive ink transfer. Maintain proper ink viscosity for smooth application. Regularly inspect and replace damaged plates. 4. Registration Issues (Misalignment of Colors) Cause: Improper plate mounting or press settings. Solution: Use a precise plate mounting system with optical alignment. Check and adjust press registration settings before production. Ensure plates are mounted securely to avoid movement. 5. Plate Cracking or Premature Wear Cause: Incorrect plate material or excessive cleaning with harsh chemicals. Solution: Choose durable, high-quality photopolymer plates. Use gentle, approved cleaning solutions. Store plates properly to prevent exposure to UV light and heat. 6. Inconsistent Ink Transfer (Ink Not Sticking Properly) Cause: Improper plate surface treatment or ink compatibility issues. Solution: Use plates with correct surface treatment for better ink receptivity. Ensure ink formulation is compatible with the plate material. Adjust anilox roll specifications for better ink release. 7. Air Bubbles Under the Plate Cause: Poor mounting technique or dust contamination. Solution: Clean the mounting surface thoroughly before application. Use a squeegee or roller to press the plate evenly onto the tape. Apply the plate slowly and carefully to avoid trapping air.

🖨️ Printing Defects: Are You Solving Them… or Just Guessing? Every printing press faces it — 👉 Shade variation 🎨 👉 Ghosting 👻 👉 Smudging ✋ 👉 Misregistration 🔄 But here’s the truth: printing problems aren’t random. Each one has a cause, a measurable parameter, and a standard-based solution. That’s why I created the Offset Printing Troubleshooting Matrix (ISO 12647-2 Based). It’s not just a checklist — it’s a roadmap to consistent print quality: ✔ Clear problem definition ✔ Root causes identified ✔ Standard parameters applied ✔ Corrective actions documented 📑 Attaching the full matrix here 👇 Because when we follow standards, quality becomes predictable — and trust becomes unshakable. 💡 Question for you: Which printing defect drives you crazy the most? #OffsetPrinting #PrintQuality #ISO12647 #QualityControl #PackagingIndustry #ContinuousImprovement #PrintProduction #LeanManufacturing #Troubleshooting #ProcessExcellence.