Learn the differences between surface printing and subsurface printing on aluminum. Compare durability, print quality, lead times, and costs to choose the best printing technique for your application.
A custom design, such as text, a logo, an image, or an illustration, can be applied to an aluminium name badge, key tag, or logo plate using one of two printing techniques: surface printing or subsurface printing. In this article, we explain the differences between these methods and outline the advantages and disadvantages of each.
With surface printing, the design is printed directly onto the aluminium. The ink remains on top of the surface, meaning you can feel the print when you run your finger across it. Because the ink sits on the aluminium rather than inside it, the print is more susceptible to wear and damage when used frequently.
One of the biggest advantages of surface printing is that all colours, including white, can be printed. This is not possible with subsurface printing. However, the design cannot extend completely to the edge of the product. A narrow aluminium border will always remain visible around the artwork.
With subsurface printing, also known as hydro-anodizing, the design is first applied to untreated aluminium. The aluminium then undergoes a chemical anodizing process that seals the artwork beneath the anodized layer. As a result, the print becomes part of the aluminium itself instead of sitting on the surface.
This makes the print highly resistant to wear, scratches, water, and weather, making it an excellent choice for products that are used intensively every day. Since the print is embedded in the aluminium, it cannot be felt by touch.
Another advantage is that subsurface printing allows for full-bleed printing, meaning the design can extend all the way to the edges. However, white and very light colours cannot be reproduced. During the anodizing process, white areas become the natural silver colour of the aluminium.
The right printing method depends on how the product will be used.
Choose surface printing if you:
Choose subsurface printing if you:
For applications such as industrial nameplates, asset tags, key tags, machine labels, and identification plates, subsurface printing is generally the preferred choice due to its outstanding durability. Surface printing is an excellent alternative for prototypes, promotional items, and smaller production runs where speed and flexibility are more important.
