1. Primer
A high-strength stainless steel alloy bonding layer (NiCr) is used to ensure a strong bond between the ceramic layer and the metal roller surface, effectively preventing solvents in the ink from penetrating the base roller. The thickness of the NiCr alloy bonding layer is 0.1 mm.
2. Plasma Spraying
A strict process is used for plasma spraying of the ultra-hard ceramic layer (Cr2O3) to ensure the porosity, thickness, and uniformity of the ceramic layer.
Requirements for the Cr2O3 ceramic layer: thickness: 0.20–0.25 mm; hardness: HV1250–1350; porosity: ≤1%.
3. Engraving
High-power, high-precision laser engraving equipment is used to engrave the mesh shape, ensuring a regular shape, smooth mesh walls, flat mesh bottom, high ink capacity, and easy cleaning. The mesh depth is 0.008–0.09 mm, uniform, and has good ink transfer capability.
Mesh aperture ratio: The ratio of mesh depth to the number of openings. A suitable ratio is 23%–33%, with an optimal ratio of 28%.
Shallower meshes result in smaller mesh volume and lower ink transfer. Deeper meshes allow for greater ink transfer, but they are more prone to clogging, hindering ink transfer and cleaning.
Deeper meshes (for the same opening size) also lead to: excessively wide mesh walls, resulting in uneven ink transfer and a non-uniform ink layer; uneven mesh bottoms, making ink clogging easier; and impaired ink transfer capabilities.
A reasonable mesh count, ink transfer volume, mesh aperture ratio, and mesh wall width can enable ceramic anilox rollers to achieve a uniform ink layer and excellent ink transfer performance.
