Custom printed hair foil
We print hair foil by gravure, in up to 9 colours. Each colour in a design needs its own plate, at 92 USD per colour, and a design has a minimum order of 3,000 boxes per design. The repeat spacing along the foil is set for each design and its plates.
Printing methods
Three printing methods are used on aluminium foil. They differ in set-up cost and in the run length they suit.
| Method | How it prints | Set-up | Suits |
|---|---|---|---|
| Gravure | Engraved cylinders carry the ink | Highest: a cylinder for each colour | Long runs and repeat orders |
| Flexographic | Flexible relief plates carry the ink | Lower: a plate for each colour | Medium runs |
| Digital | Ink is applied without plates | Lowest | Short runs and samples |
Our hair foil is printed by gravure, in up to 9 colours.
Artwork requirements
| Item | Requirement |
|---|---|
| File format | AI or PDF, vector, with text converted to outlines |
| Colours | Pantone references, one for each printed colour |
| Number of colours | Up to 9 colours |
| Repeat spacing | Set by the design and the plate plan. For an all-over small logo, a design can start from a 50 mm repeat; that is a design suggestion, not a minimum |
| Fine lines and small text | Checked against your artwork before plates are made |
| Bleed | None on the foil: the design is a continuous repeat |
Two points catch first-time buyers. The design is a repeat that runs the length of the foil, and sheets are cut from it without registering to the repeat, so a logo will sit at a different height on each sheet. And the foil is silver unless a background colour is printed, so any area you leave unprinted shows as bare aluminium.
Box artwork follows different rules, with bleed and safe areas. The templates are on dielines and artwork templates.
Colour matching
Colour on foil is matched to a Pantone reference, and judged on foil.
- You give a Pantone reference for each colour.
- We print a sample on the foil and the surface you have chosen, smooth or embossed.
- You approve the sample, or ask for a correction.
- The approved sample is kept as the reference for later batches.
The same ink reads differently on smooth and on embossed foil, and on a light and a heavy pattern, so the sample is made on the surface the order will use.
Plate costs and reuse
Plates are charged once for each design, one plate per colour: 92 USD per colour. A change to the artwork that alters what is printed means new plates for the colours affected. A change of foil size alone does not, because the same repeat is cut to a different length.
How long plates are kept, and what a reorder costs, is stated on your quotation.
Ink safety
Printed foil can be tested in bleach with developer before a design goes into production. The method is on printed hair foil ink vs bleach: how we test. The print limits in summary, with the minimum order, are on the printed and coloured hair foil page.
Printing FAQ
What file format do you need for printed hair foil?
For printed hair foil, send vector artwork as an AI or PDF file with text converted to outlines and each colour given as a Pantone reference. Vector artwork scales to the plate without losing sharpness. A logo in a raster format such as JPG or PNG is enough to start a quotation, but not to make plates.
How much does a printing plate cost?
Printing plates for hair foil cost 92 USD per colour at Hair Foil Factory. Each colour in the design needs its own plate, so a design with more colours costs more to set up. The plate cost is charged once per design.
Can you print on both sides of the foil?
Hair foil is normally printed on one side: the side that faces outwards when the foil is folded around the hair. Whether both sides can be printed depends on the press. Tell us if you need it, and we confirm before quoting.
How close can you match my brand colour?
A brand colour is matched on hair foil to a Pantone reference and approved on a printed sample. Ink on reflective aluminium looks different from ink on white paper, so the match is judged on foil. The sample you approve is the reference for every later batch.
Do I pay for plates again on reorder?
Plates for printed hair foil are charged once per design. Whether they are charged again on a reorder depends on how long they are kept and whether the artwork has changed; the plate terms for your order are stated on the quotation.