Cylindrical DTO Printing is Revolutionizing Drinkware, Packaging, and Personalization

ABOVE PHOTO: When it comes to DTO cylindrical printing, runs of one can be as cost effective per item as runs of thousands, making on-demand production a real possibility.

DIGITAL PRINTING IS reshaping the print industry, offering capabilities that were once out of reach for many producers. While traditional screen printing remains dominant in segments like textiles and apparel, digital technology is gaining ground, particularly among businesses looking to diversify. For companies embracing short runs, print-on-demand, and personalized production, digital printing isn’t just a tool for operational flexibility. It’s a gateway to entirely new markets.

Cylindrical direct-to-object inkjet (DTO) printing is one of those technologies that breaks down barriers. Specially designed fixtures hold each item to be decorated, rotating it while tiny droplets of UV-curable ink are jetted onto it by a print head before an ultraviolet (UV) light activates a chemical reaction that instantly “cures” the ink.

This makes it possible to produce full-wrap, full-color images on most cylindrical items, whether straight-walled or tapered. And because this instant curing also ensures that no “bleeding” (or spreading) of ink droplets occurs, the technology makes for precise reproduction of vividly colored digital images, as well as fine lines, text, and numbering.

The advantage of digital cylindrical DTO printing on candle holders is the flexibility. It enables by maximizing run lengths and setup time, as well as the ability to add special effects and level of personalization them.
All additional images courtesy of Inkcups, Danvers, MA

Dip into Dramatically Decorated Drinkware

For many screen-printing businesses, decorating drinkware has been a staple application for many years, albeit with limitations. Order volumes needed to be reasonably high to make them cost-effective, and graphics could be striking but needed to feature fewer colors. With the advent of digital printing technologies such as dye sublimation, it became possible to increase the complexity and coloration of design, as well as slightly reduce minimum order numbers.

However, the development of cylindrical inkjet printing technologies has changed the game completely, making it possible to produce single items as cost-effectively as hundreds of them. This takes minimal setup, little cleanup is required and it’s ideal for application on a variety of substrates.

In addition to producing vibrant 360° images on cylindrical items such as stainless-steel tumblers, disposable cups, thermoses, sports bottles, and glassware. Another part of cylindrical DTO inkjet printing’s appeal is the wide range of striking special and tactile effects that make it possible when clear varnish is applied and cured in the same way as inks.

Tone-on-tone varnishing, for example, can be used to highlight the sheen of metal to create a “wet” look, while a luster effect allows for metallic shades on aluminum, stainless steel, and other cylindrical metal drinkware and bottles.

Meanwhile on glass drinkware and bottles, an etching effect can be achieved by using white ink at a lower opacity, while stacked varnish can create an embossed effect. Stained glass effects can also be achieved by printing color only and allowing light to shine through, and a mirror print is also possible on glassware, with the same artwork visible from both the interior and exterior of the glass.

A luster effect on products such as drinkware allows for metallic shades on aluminum, stainless steel, and other cylindrical metal bottles.

Plunge into Personalization

One of the biggest advantages of DTO printing is that, beyond artwork preparation, which can be relatively easily automated, there is little setup time entailed in the process. As a result, runs of one can be as cost effective per item as runs of thousands, making on-demand production a real possibility. It also opens up opportunities in personalization and mass customization.

For those already capitalizing on the explosive growth in decorated drinkware, personalization is the next step. The consumer print-on-demand and gifting markets are driving demand for personalization on an unprecedented scale, and drinkware is no exception. This isn’t just about “World’s Greatest Grandma” mugs or “No. 1 Dad” beer glasses. It’s also photo-printed and hyper-personalized products that consumers seek out almost as an extension of their identity.

Custom Cans and Bespoke Bottles

Of course, opportunities in personalization don’t stop at drinkware. Another of the market segments driving demand for customization is packaging, with the rise of independent cosmetics brands, craft breweries, boutique wineries, and artisanal distilleries. Additionally, white-labelled products for the hospitality industry are creating enormous opportunities for those able to produce low-volume, high-end packaging as it is needed.

One lucrative market segment driving demand for customization is packaging, with the rise of independent cosmetics brands, craft breweries, boutique wineries, and artisanal distilleries. 
Image courtesy of Bottled Goose West Molesey, Surrey, UK, and is printed using the Inkcups’ Double Helix.

Capitalize on the Candle Craze

Another trend, that of personalizing candle holders, has surged in popularity for occasions like weddings, holidays, and special birthday celebrations, and for gifting and in the hospitality industry. Of course, candle holders are another application with which some screen-printing companies are already familiar. But the advantage of digital cylindrical DTO printing is the flexibility. It enables this in terms of run lengths and setup time, as well as the special effects and level of personalization it
can achieve cost-effectively.

Cylindrical DTO printing technology makes it possible to not only produce tactile effects and edge-to-edge, but also 360° graphics on straight-sided and tapered cylindrical objects. To do however, cost-effective procedures on-demand and in-runs as small as one or as large as n thousand must be implemented. For creative businesses considering a move into DTO, the opportunities may not quite be 360°, but they’re certainly all around.