Add brilliance to your documents with Toner Adhesion Foiling. Fuser Foil adheres to the dry toner used in most black and white copiers and laser printers. Applying foil adds brilliant metallic colored foil to black and white toner copies or printed documents. Foiling applications are very popular for wedding or other invitations, award certificates, creating borders for craft projects, adding pizzazz to business cards or letter head, and anything else that could benefit from bright metallic color accents.
What is foil fusing? - Foil fusing is a process where foil is bonded to a toner image area that was created using either a laser printer or a copy machine. Foil fusing does not require any type of die. Laser printer and/or copy machine toner is used to bond the foil to the paper. There is no make ready or other special skills required to produce foil fusing.
Foil fusing only requires that the foil width be slightly wider than the toner image area to be foil fused. Using foil cut slightly wider than the image area, plus the ability to run sheets portrait or landscape helps to minimize foil waste and expense. The maximum paper thickness for foil fusing is based on the maximum sheet thickness you can run on your laser printer/copy machine.
How to apply foil - There are 2 ways to apply the foil.
First, the Thermotype FT-10 is a dedicated foiling machine. It uses rolls of foil and applies them with a heated roller similar to the way a laminator applies laminating film. However, the foil only sticks to where there is dry toner.
Second, you can apply foil using any heated roller pouch laminator. Simply cut the foil out to the size you want to apply foil on your paper sheet, placing the foil over the desired location, inserting the paper and foil into a carrier and the running it through the pouch laminator.
Questions and Answers on Foil Fusing
What is foil fusing? Foil fusing is a process where foil is bonded to a toner image area that was created using either a laser printer or a copy machine.
What types of foils are available for foil fusing? Gold, sliver, metallic colors, pigment colors, and special application foils like glitters, as well as, decorative and security holographic patterns.
Is a die required to produce foil fusing? No foil fusing does not require any type of die. Laser printer and/or copy machine toner is used to bond the foil to the paper.
Can a foil fuser be used to produce blind or foil embossing? A a blind or foil emboss effect can not be created, a foil fuser can only apply flat foil and be used to "thermo-fuse" sheets with a toner image area.
Are all laser printer and copy machine toners compatible for foil fusing? No, some laser printers and copy machines with certain toners are not suitable for foil fusing. If you have any questions about the suitability of your printer and/or toner, we will be happy to run compatibility tests on your samples.
Does fusing foil only stick to black toner? No, fusing foil will fuse to all toner image areas regardless of color.
Are any special skills required to produce high quality foil fusing? No, there is no "make ready" or other special skills required to produce foil fusing. When using compatible papers, printers/toners and foils, operators are only required to set the appropriate speed and temperature for the type of foil and paper being run.
How much does it cost to foil fuse an 8-1/2" by 11" area with gold foil? Foil costs vary but customers usually figure about $.06 per 8-1/2" by 11" sheet for gold or silver metallic foil. Keep in mind that metallic colors, pigment and special application foils are typically more expensive than gold and silver.
Do I need a foil cutter? - Yes and no, customers can purchase foil pre-cut to specific widths but this is often inconvenient and wasteful if you wind up being forced to run a job with a roll that is wider than necessary. Purchasing foil in 24" wide rolls, then cutting the specific width required for each job will minimize foil waste and cost.
Do you have to run a foil width that matches the paper width? No, foil fusing only requires that the foil width be slightly wider than the toner image area to be foil fused. Using foil cut slightly wider than the image area, plus the ability to run sheets portrait or landscape helps to minimize foil waste and expense.
What is the maximum paper thickness that can be foil fused? The limiting factor in maximum paper thickness while foil fusing is based on the maximum sheet thickness you can run on your laser printer/copy machine.
Can the foil draw be controlled to match the length of the image area to minimize foil waste? No, there is no foil draw control on a foil fuser. When paper is being fed through the machine and the impression is engaged, foil is drawn at the linear rate of the paper. Foil waste can be minimized using the proper foil roll width and by how the sheet is run through the fuser.
Can rewound foil or fusing film be reused? No, foil fusing film that has been through the fusing mechanism and rewound is waste.
What happens when toner is applied over offset ink? The foil will only adhere to the toner image area and will not transfer to the offset ink.
Can I lay down two or more colors of foil within the same image area if the foil areas don't overlap? Yes, imprint toner and foil fuse the first color, then apply the second toner image area and foil fuse the second color. All foils have different "laser proof" characteristics, customers need to understand these and their laser printer/copy machine characteristics
Can I produce tight registration, multicolor foil images by running the sheet through the laser printer/copy machine and fuser multiple times? No, laser printers and copy machines can not accurately register multiple images imprinted in multiple passes.
Can I foil fuse stocks that are not perfectly smooth, like laid? Some lightly textured papers can be foil fused. However, foil fusing will not crush the texture flat like traditional foil stamping. As a result, the paper surface texture will show through the fused foil. Foil fusing results on even lightly textured stocks can be unpredictable.
Do different papers affect the foil finish when foil fusing? Yes, compatible very smooth or coated stocks will provide more of a mirror finish when fusing bright finish gold, silver and metallic colors. Compatible uncoated stocks will foil fuse well but with less of a mirror finish. Keep in mind, paper type and finish also affect the foil finish that can be achieved using traditional foil stamping.
How does paper thickness affect foil fusing? Foil fusing is a heat process, as a result, thicker papers will require a higher fusing temperature and more dwell time or slower output speeds than thinner papers.
How can I maximize foil fusing speed? Foil fusing productivity is based on a linear fusing rate for a given type and thickness of paper. Running sheets landscape, whenever possible will maximize through put.
What is the smallest type that can be used with foil fusing? We recommend 6 pt type as a minimum size that can be foil fused without letter plugging. Results may vary depending on the type of printer/toner, foil and paper used, and the fusing speed and temperature.
Can I combine large solid areas at the same time I am fusing small type? Yes, one of the interesting characteristics of foil fusing is that you can fuse large solids at the same time you are fusing small, fine line type.
Can sheets be run through an offset press after they have been foil fused? Yes, offset printing and/or printing with a digital duplicator will not affect the foil image area.
Can foil fusing be used for security applications? Yes. There are three transparent and three silver holographic security foils currently available. These foils have micro text patterns. Some customers also use standard holographic pattern foils as a security enhancement.
What are transparent holographic pattern foils and how are they used? Transparent holographic pattern foils are used to apply a holographic pattern effect over single, spot or full color text and graphics. These foils can be used to create a wide range of visual effects.
Can I use white fusing foils on dark colored stocks? Yes, white pigment foil can be fused on dark stocks, including black. White is currently a very popular fusing foil color.