Design alterations were suggested to reduce foil coverage requirements, which led the designer to the concept of the ‘embossed’ veins in the butterfly wings. This approach utilized crease lines created through the stamping process as an actual design element – creating a unique look to the piece that reduced makeready times, increased foil selection options, improved production rates of speed and overall quality level of the piece. After the final design was completed, BrightMARKS reviewed stamping die requirements with Universal Engraving, Inc. (UEI), Overland Park, Kan.; foil requirements with API Foils, Rahway, N.J., and Infinity Foils, Inc. (a UEI Group Company), Lenexa, Kan.; glitter requirements with Infinity Foils, Inc.; and trim and binding margins with Laser Excel and Constable Bindery, Inc., Kansas City, Mo.
The piece was produced on Pegasus 130lb. DT cover, two-up. Three passes of foil were stamped in tight registration to each other - black metallic, copper 2-D holographic, and silver metallic. Copper stamping dies were utilized with a special custom Unifraxion® die created for the silver stamped areas. Artwork for the detailed etched effect in these areas was designed by Eric Carter to emulate the graceful movement of a butterfly wing. The sheets then were glitter UV coated two-up, using proprietary techniques and a custom glitter UV blend. For the finishing touch, a delicate laser cut butterfly wing (shaped out of 130lb. Pegasus cover) was produced by Laser Excel as an overlay to the stamped cover. Finally, the press sheets were sent to Constable Bindery for trim (matching with the laser cut wing) and black plastic coil binding.
According to FSEA Executive Director Jeff Peterson, “This type of publicity and beautifully crafted directory cover is made possible only through the backing of dedicated FSEA members. It is a great example of a collaborative effort in design, tools, materials, equipment, and operators that really paid off in the end!” For more information on the Foil & Specialty Effects Association (FSEA), visit www.fsea.com.