The Metalphoto Process

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A durable, black Metalphoto image is the result of a number of interrelated processing steps.  Beginning with exposure and concluding with sealing, each of the processing steps is critical and each must be understood in order to achieve the quality and durability characteristics for which Metalphoto is known.  The process is simple but not to be underestimated.  Mastering the process will allow you to produce labels, nameplates and panels that are among the most durable in the world.

Immediately below is a short video that will allow you to view the basic Metalphoto process.  Beneath the video are step-by-step process descriptions.  We invite you to watch and to refer to the steps that follow for additional information.  Complete information may be found in our on-line Imaging Guide.

 

 

Step 1 :: Create artwork using a drawing program such as CorelDRAW, AutoCad<br />or PhotoShop. Step 1:
Create artwork using your choice of commercially available software programs.
Step 2 :: The Metalphoto family of photosensitive anodized aluminum products require a<br />high contrast film, negative or positive, to produce an image. You can make the <br />film through traditional wet photographic film processing equipment, direct to<br />film dry thermal imagesetters, film substitutes, or through your local<br />film service bureau. Step 2:
Generate high contrast film negatives or positives by outputting the artwork created in Step 1 above.  Film output options include traditional photographic film processing equipment, imagesetters and now, the Xerox 7500 laser printer system available from Horizons .  Film service bureaus remain an option as well.
Step 3 :: Select a Metalphoto plate from the broad array of standard thicknesses, finishes,<br />and sizes available.

Step 3:
Select an appropriate Metalphoto plate from among an array of sheet sizes, thicknesses and finishes.
Step 4 :: Expose the Metalphoto plate through the film negative in a contact vacuum<br />exposure frame. Typical exposure times are between 5 and 30 seconds,<br />depending on copy. After the next processing step, the areas on the plate that<br />are exposed to light turn black and those not exposed to light, remain silver.

Step 4:
Expose the Metalphoto plate through the film negative or positive generated in Step 2 above.  Typical exposure times are between 5 and 30 seconds in a contact vacuum exposure frame.   Areas on the plate that are exposed to light become activated and will become black following the processing described in Step 5 below.  Unexposed areas will remain silver or natural aluminum in color.
Step 5 :: After exposure, simply feed the plate into the ZIP Processor where it is<br />automatically developed and fixed. From this point in the process, the plate is no<br />longer photosensitive. It is fully imaged with black and silver copy and is ready<br />for the final processing steps.

Step 5:
The plate that has been exposed in number 4 above is automatically processed in a Metalphoto Zip Processor where precise amounts of Developer and Fixer fluids are applied.  When a Metalphoto plate exits a Zip Processor it is fully imaged, no longer photosensitive and ready for the final processing steps.

A range of Zip Processors are available.  Our Representatives will work with you to help determine which Processor will be most suitable given your current and future needs.
Step 6 :: Rinse the processing fluids off the plate by placing it in a Metalphoto Rinse<br />Tank Unit that simultaneously rinses both sides. Up to this point in the process,<br />the anodized layer of the plate is unsealed. In fact, Zip processing, rinsing, as<br />well as any additive color steps, occurs within the unsealed anodized layer.

Step 6:
Depending on the Zip Processor, plates that have been imaged in number 5 above may be damp with fixer.  In that case, rinsing must now take place.  Rinsing may be done in a sink or by placing the plate in a specially constructed Metalphoto Rinse Tank.  Both immersion and spray rinse tanks are available.
Step 7 :: Optional Steps - Image Intensifying Metalphoto plates or adding background<br />or selective/spot color is easily accomplished and takes place prior to sealing.

Step 7:
Optional Steps:  Image Intensifying;  Addition of Color
Image Intensifying to enhance both the heat and UV resistance of Metalphoto plates or adding background or spot color is easily accomplished and takes place prior to sealing.
Step 8 :: To finish the Metalphoto plate and provide for the unique durability, this plate<br />must be sealed by immersing it in a Metalphoto Sealing Tank Unit filled with<br />a heated sealing solution.

Step 8:
The final step in the process is most critical in terms of ensuring the unique durability characteristics for which Metalphoto is known.  This involves sealing the plate by immersing it in a Metalphoto Sealing Tank filled with a heated solution comprised of distilled or deionized water and sealing concentrate additive.

The effect of sealing is to close the still open anodized pores.  As the pores close, the developed and fixed Metalphoto image becomes trapped or buried within the aluminum oxide layer and the result is an incredible and long-lasting subsurface image.
Step 9 :: After sealing, the Metalphoto plate will require finishing. Typically, this includes<br />the application of adhesives and then shearing, punching, drilling, bending<br />or other fabrication.

Step 9:
After sealing, the Metalphoto plate is typically fabricated in one of several ways with the result being a finished Metalphoto part.  Fabrication options include the application of adhesive, shearing, die-cutting, punching, drilling and bending.  A range of fabrication equipment is available depending on your needs.
Step 10 :: Finished Metalphoto Anodized Aluminum Parts.

Step 10:
Voila!  Finished Metalphoto Photo Anodized Aluminum Parts.

 

Metalphoto Imaging Guide

Because every step in the Metalphoto production process is forgiving to some degree and because Metalphoto has a track record that spans decades, it is easy to underestimate the fact that when running Metalphoto, converters are engaged in and responsible for an industrial, photographic process.  The process is not difficult but it is to be understood, mastered and respected.

Below are links to specific sections of our on-line Imaging Guide.  They are presented for the purpose of providing the user with guiding principles as well as the complete details of Metalphoto processing.  Please think of the guide as a tool to be used for on-going reference and training.  Our objective is to provide your organization with complete understanding of what is happening throughout the production process and how to perform each step.  With knowledge comes a real opportunity for you to improve quality, increase productivity and enjoy a robust and profitable Metalphoto processing experience!

Downloadable Metalphoto Imaging Guide:

Horizons ISG is a division of Horizons Incorporated

About Horizons

 

Consisting of five operating divisions, Horizons Incorporated is a high value, high quality manufacturer of a diversified family of materials and product identification items.  Selling in markets around the world and with corporate offices in Cleveland, Ohio, USA, these divisions include Horizons Imaging Systems Group, MPC, Camcode, Pannam Imaging and Lasting Commemoratives.  Horizons Imaging Systems Group (ISG) is the largest of the divisions and represents the raw material and systems side of the business.  ISG sells to an international mix of independent Converters, Dealers and OEM's.

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