Technical Bulletin #26
Date: December 1, 2000
Subject: New Materials and Templates Available
Direct Color Systems recently introduced several new pre-cut materials in popular badge and plate sizes. This bulletin will address additions and changes to the existing product line and will introduce .CDL template files available for use with the new products.
Template Files
Template files are Color Byte files that define where to place text and graphics on precut blanks. Guidelines are in position to show the vertical and horizontal centers of each "part" and hairline rectangles (or circles) are pre-placed to indicate precisely where text/graphics should reside. Here are two examples of our pre-made files that make positioning easy for the user:
Template files can be found on the DCS web site Downloads page. To use the templates, copy the file to your hard drive, open it in Color Byte, then perform an immediate "Save As" assigning the file a name of your choice. Performing a "Save As" assures that the master file (template) is retained for future use.
Since Color Byte saves printer driver settings with the file, it is important to make sure that you open the Calibration tab in Printer Setup and "set" the calibration to your printer’s Center in Driver figures. The calibration settings for each Millennium printer are slightly different. Using the calibration figures saved with the template file may result in your printed image being off-center. Always attend to this important step. Open the Calibration tab and input the Center in Driver figures found on the white label affixed to the back of your printer.
The Center in Driver figures found on the back of your printer are the center for a 1-1/2" x 3" blank [38.1mm x 76.2mm]. Center for a CR-80 blank may be slightly different. To insure that you have precise center figures for a CR-80 blank, follow these instructions:
-
Open a new Color Byte file and set the Blank Size in Layout at CR-80 size.
-
Using the Rectangle Tool, draw a rectangle the exact size of the Sign Blank. Fill the rectangle with Black.
-
Place several CR-80 cards in the printer’s Card Hopper.
-
Print the file, being sure to use the Calibration figures found on the printer label (Center in Driver).
-
If the image is not centered, adjust Calibration figures in Setup/Calibration to the point where the image IS centered on a CR-80 blank.
-
If adjustments were necessary, retain the adjusted figures and write them on the printer label for future use. For example, write: Template Center in Driver: V = -5, H = 3
-
Always use the Calibration figures found on your printer label OR the adjusted figures arrived at by following the steps above when using a .CDL template file.
In addition to attending to Calibration Setup figures, be sure to make all other printer driver Setup choices appropriate for your job. For example, be sure to select the correct Ribbon, Color Control settings, and other desired driver options.
Template files are available for the following products:
-
3-Up Trophy Plates
-
3-Up Trophy Plates / Badges Function
-
2-Up Badges
-
2-Up Badges / Badges Function
-
1-Up 2" [50.8mm] Trophy Disc
-
4-Up 1" [25.4mm] Trophy Discs
-
3-Up Key Tags
Template Files and the Badges Function
It is possible to use template files in conjunction with the Badges function in Color Byte. The Badges function lets you take a list of names and merge them into the file so that each individual badge or plate has different text information. You can also use the Badges function when you want to print multiple copies of the same plate. When using the Badges function, you need only place text and graphics on ONE plate or badge. The software does the rest.
The templates for use with the Badges function have Notes included that tell you what settings need to be attended to in the Badges dialog box. Use the settings information provided, substitute your text, and the software will merge your text names and position each badge or plate correctly. Here are examples of a Badges function template and a the resulting file after the Badges function has been performed:
3-up Trophy Plates
DCS redesigned the .020" thick [.5mm] 3-Up Trophy Plate blank to make it easier to feed through the Millennium printer. The new blank’s overall dimensions are 2.125" wide x 3.375" long [54mm x 85.7mm] — the size of a CR-80 card. Individual plates measure .625" wide by 3" long [15.9mm x 76.2mm]. Note that the width of the new plate remains the same as the old design, while the length has increased slightly (from 2.75" to 3.00" [70mm to 76.2mm]).
In addition to making the blanks larger to accommodate smoother feeding, we have also changed the fabrication method employed for scoring the blanks. These products are now laser cut from the back resulting in a cleaner front surface when the plates are perforated. Removing individual plates from the blank requires bending the material forward towards the front, or PrintMark side. This is opposite the old removal method.
Grasp the blank in your hands, PrintMark side facing down and paper masking side facing up. Perforate the end tab first. With your thumbs resting on the plate portion of the blank and your forefingers resting on the tab portion of the blank, flex the blank down until the perforation separates. Don’t be afraid to apply significant downward pressure. Often you’ll need to flex the card down 90º before it actually perforates. Follow the same procedure for other score lines.
An alternative removal method is to place the blank on a hard, flat surface print side facing up. Use both hands to flex the blank up at the score line. Remove the end tab first, then remove the individual plates.
2-up Badges
2-Up Badges are a new addition to the DCS material product line. The blanks are made from .052" [1.3mm] thick PrintMark II stock and are the size of an Oversize card (2.5" x 3.7" [63.5mm x 94mm]). Each card contains 2 badge blanks measuring 15/16" x 2-15/16" [23.8mm x 74.6mm]. This size just shy of a 1 x 3 badge allows for the badge to fit nicely inside any standard badge frame. And the 2-up format allows for full bleed imaging across the entire surface of the badge without any post-operation labor.
Badge blanks are laser-scored. Remove individual badges from the blank by placing the blank on a hard, flat surface print side facing up. Remove both end tabs first. Grasp the tab with both hands and flex it upwards until the tab snaps off. The flexing will require a bit of effort. Once the end tabs are separated, flex across the other blank score lines to remove the individual badges.
If you need further assistance in upgrading your printer, please contact DCS technical support at techsupport@directcolorsystems.com or the same via phone at 860-829-2244.
