Synthetic Media vs. Lamination

For most applications, a case could be made both for and against using synthetic media. Jeremy Underhill, vice president of sales at MGX, compares synthetic media and lamination.

“Lamination can provide superior durability as the inks or toner are protected from wear and abuse, but can be excessive for some applications as well as prohibitively expensive,” he notes. “Not all lamination is created equal.” He further breaks down the options:

• Encapsulated or sealed edge lamination sandwiches the printed material or core between layers of laminate film, which extend past the edge of the piece. This prevents moisture from entering through the edges for the highest level of durability. As a result, you have more flexibility and economy in core material selection as the durability and expense are in the laminate itself. The downsides of sealed edge lamination are cost and aesthetics. Again, the laminate and process are expensive and time consuming, especially for larger runs. It also yields a less professional appearance with the laminate overhanging the printed material, which can have a negative association for some customers.
• Flush cut lamination is also an option and involves film laminating a printed piece and trimming or die cutting the piece such that the laminate is even or flush with the interior material. This yields an improved aesthetic and full bleed appearance. While the front and back of the piece is fortified and more durable because of the lamination, the exposed edges allow for moisture intake, which can cause bubbling and delamination if a paper core is used. To prevent moisture absorption, a synthetic core material can be used, but the bond between layers is critical for longevity.
• Printing on synthetic paper is a great way to balance durability and economy. Again, synthetic paper provides similar durability to lamination, but without the cost, time, and labor of film lamination. It also yields the cleanest, most professional appearance. Ink or toner adhesion and durability are critical, however, to the durability equation. In high use and demanding applications like menus, the use of UV coatings can help protect ink / toner and extend the life of the piece.