Process Capabilities
FORMflex has endured many obstacles presented by changes in our global economies and markets through flexible service and quick response. In response to ongoing requests from our customers and reaction to the market changes, we are constantly expanding our capabilities.
The information that follows is intended as guidance to assist in the development of products from concepts presented by our customers. Many of the limitations listed may be overcome through alternative design, variation in construction or the utilization of one of our strong alliances developed with outside resources over the years we have been in business. Call FORMflex customer service to discuss your options.
Extrusion
Polyethylene
| Surface | Gauge | Min Width | Max Width | Min Length | Max Length |
| Matte | .014 - .054 | 9" | 48" | 9" | 60" |
| Matte | .055 - .250 | 9" | 48" | 9" | 96" |
| Crush | .018 - .054 | 9" | 48" | 9" | 60" |
| Crush | .055 - .250 | 9" | 48" | 9" | 96" |
| Co-ex | .020 - .054 | 9" | 48" | 9" | 60" |
| Co-ex | .055 - .125 | 9" | 48" | 9" | 96" |
Smaller minimums may be obtained through guillotine or die cutting.
Roll stock is also available - call customer service for details.
Additional surfaces and/or combinations may be possible with limitations.
Polypropylene
| Surface | Gauge | Min Width | Max Width | Min Length | Max Length |
| Matte/Matte | .020 - .054 | 9" | 48" | 9" | 60" |
| Matte/Matte | .055 - .075 | 9" | 48" | 9" | 96" |
| Matte/Polish | .020 - .054 | 9" | 48" | 9" | 60" |
| Matte/Polish | .055 - .075 | 9" | 48" | 9" | 96" |
| Diagonal/Lines | .020 - .054 | 9" | 48" | 9" | 60" |
| Diagonal/Lines | .055 - .075 | 9" | 48" | 9" | 96" |
Smaller minimums may be obtained through guillotine or die cutting.
Roll stock is also available - call customer service for details.
Additional surfaces and/or combinations may be possible with limitations.
DIE Cutting
| Process | Gauge Range | Minimum Cut | Maximum Cut | Minimum Sheet Size | Maximum Sheet Size |
| Hand Fed | .014 - .075 | ½” x ½” | 37 ½" x 53" | 5" x 5" | 38½" x 54" |
| Hand Fed | .076 - .250 | 2” x 2” | 37 ½" x 53" | 8" x 8" | 38½" x 54" |
| Automatic | .014 - .075 | ½” x ½” | 40¾” x 28¾” | 15¼” x 15¾” | 41" x 29" |
Die cutting capability may be further limited by various combinations of size, gauge and tonnage resulting from the number of punches and the amount of cutting and scoring rule.
The minimum sheet size restriction of 5" x 5" & 8" x 8" may result in higher material and/or die costs.
Cold scoring in the die is recommended for products .055 gauge or less.
Blind imprinting is available for the cost of the dies on most products and must consist of outlines and fine lines - no bold face type is permitted.
See our standard die templates here for some of our options and sizes.
Screen printing
| Process | Gauge | Minimum Image Area | Maximum Image Area | Minimum Sheet Size | Maximum Sheet Size |
| Hand Fed | .014 - .250 | see screen printing guidelines | 36.5" x 50" | 6" x 6" | 37.5" x 54" |
| Automatic | .014 - .040 | see screen printing guidelines | 27" x 36" | 15" x 24" | 28" x 40" |
Four-color, halftones, & tints may require a larger minimum size sheet at an additional cost.
Artwork should be set up to actual size of the product and may be submitted on a separated mechanical or disk.
Minimum type size for good reproduction is 6 points and minimum line weight is .65 points.
Bleeds should be restricted to .055 gauge material or less and must extend 1/8" beyond the cutting area, and mock bleeds can be no closer than 1/16" from cutting edges.
Artwork should not be designed with reverses through more than one ink color and requires a minimum type size of 12 points and minimum line size of 1.5 points.
Halftones and tints should be provided at 22.5° from horizontal with round dots and screen rulings of 65 or 85 line (when overlapping two tints use 22.5° for the darkest color and 52.5° for the lighter).
Recommended gradient ranges are 15% to 85% at 65-85 line.
Four-color process screen printing angles are 7.5° for yellow, 22.5° for black, 52.5° for magenta and 82.5° for cyan.
Films provided should be one piece, right reading, emulsion up positives including register marks.
Ink colors should be limited to two colors on .014-.016 and three colors on .017-.023 with the maximum number of colors dependent on the thickness and number of overlapping colors.
See our Screen, Digital, & Offset Printing Guidelines for art preparation here.
See Examples of our screening printing here.
offset printing
| Gauge | Maximum Image Area | Minimum Sheet Size | Maximum Sheet Size |
| .014 - .035 | 39" x 27 ¾" | 20 ½" x 14 ½" | 40" x 28 3/8" |
All products being offset printed require a clear varnish or UV clear coat to reduce scuffing.
Conventional separation techniques & screen angles are recommended with up to 175 line ruling.
Our offset printers prefer to work from art on disk accompanied by a black and white, color separated proof at 100% size.
1/8” bleed allowances are required with register marks and color bars outside the bleed area.
Traps should be established between .005” - .007”.
Maximum dot density should fall between 300 & 400% with the Gray Component Replacement set at 70%.
Various proofs and bluelines are available for approval.
See our Screen, Digital, & Offset Printing Guidelines here.
See Examples of our offset printing here.
Digital Printing
| Gauge | Maximum Image Area | Minimum Sheet Size | Maximum Sheet Size |
| .004 - 3.9375 | 47.25" x 98.4375" | 6" x 6" | 47.25" x 98.4375" |
Resolution from 360 x 720 to 720 x 1440
CMYK + White + Spot Varnish
Add a UV Clear Coat for Additional Durability
Recommended for Quantities of 1000 or less, but larger quantities will be considered based on size and number up on the sheet
See our Screen, Digital, & Offset Printing Guidelines here.
See Examples of our digital printing here.
Finishing
Various finishing capabilities are available to satisfy any stage of production up to providing a completed product for drop shipment to your customer. The list that follows lists many of the more popular finishing capabilities. Please call your customer service representative if you require services not listed, or have questions regarding any limitations to these operations.
Hot Scoring - Foil Stamping - Debossing - Heat Bending
Edge Beveling - Tab Cutting - Eyeletting - Riveting
Pocketing - Sonic Welding - GBC® Punching
Wire-O® Punching - Collating - Fulfillment Labeling- Prototyping
Some of these processes may require special dies or tooling at an additional cost.
Binding for two-piece covers may be available depending on the content and product specifications.
Mechanical Punching is provided in a variety of styles for your binding needs. Please call your customer service representative for details. See our punching styles here.