A manufacturer prints sample outputs at trade fairs, everything looks perfect. Then the machine arrives at the production hall, and it turns out that the standard settings cannot handle thin foils, the inks don’t adhere well enough, and the printheads become unstable at higher speeds. This situation is familiar to anyone who has tried to implement a digital machine in demanding industrial applications.

At Qwerty, we approach this problem differently — already during negotiations with the manufacturer, we clearly state that the standard configuration will not be sufficient. The machine will undergo a thorough overhaul before it produces its first usable print. This assumption affects purchase conditions, price, and project execution. But above all, it provides something far more valuable — full control over the technology.

Why don’t manufacturers deliver perfect machines?

The answer is simple: every production facility has different requirements. A company printing labels needs different parameters than a plant producing membrane keyboards. A standard machine is a compromise — it works reasonably well everywhere, but optimally nowhere.

The manufacturer designs the device for universal applications, tests it with popular inks and typical substrates. In practice, however, companies use their own custom ink formulations, print on unusual materials, and require parameters the standard configuration cannot offer.

Therefore, serious industrial printing plants — especially those working with non-typical substrates — must adapt the equipment to their needs. The question is: outsource this to the manufacturer, at the cost of warranty and flexibility, or take control of the process?

Negotiations begin with giving up the warranty

At the time of purchase, we inform the manufacturer that the machine will be modified. This declaration changes the entire negotiation dynamic. The manufacturer knows they will not be responsible for service; therefore, pricing becomes more flexible. We, on the other hand, gain the freedom to introduce modifications without fear of losing technical support — because we consciously reject it.

It sounds risky, but it only works when the company has real competence to service the equipment independently. Without such experience and technical facilities, this decision would be irresponsible. However, having our own team of engineers, electronics specialists, and service technicians changes everything — a failure no longer means weeks of downtime waiting for parts and an authorized technician.

A failure becomes a technical challenge, not a production disaster. Diagnosis, parts sourcing, repair — everything happens in-house, often faster than through standard warranty procedures.

Mechanical adaptation to production requirements

The first area of adaptation is mechanical construction. Standard machines often rely on sheet-fed media handling, which works for typical advertising print applications. In industrial production, where efficiency and continuity matter, a roll-to-roll system is required. Rebuilding this element is the foundation for further modifications.

Equally important is modernizing the vacuum table. Thin foils — the primary material in membrane keyboard production — tend to wrinkle and lift during printing. The standard table cannot always stabilize them, resulting in inconsistent prints and quality issues. A redesigned vacuum system ensures that even the most delicate substrates remain perfectly flat throughout the printing process.

The next step is reinforcing the machine’s structure. Vibrations — often invisible to the naked eye — have a direct impact on print precision. The higher the resolution and speed, the more noticeable even minimal vibrations become. Additional stiffening and professional elimination of vibration sources increase process stability and repeatability.

Temperature control must not be overlooked — a frequently underestimated factor with fundamental impact on print quality. Each ink has a specific temperature window in which adhesion and drying are optimal. The heating and curing systems must be precisely tailored to the inks and substrates in use. Standard factory settings are designed for popular inks and substrates — rarely sufficient in specialized applications.

Firmware and waveform — controlling every ink droplet

The real magic happens at the electronic and software level. Access to the machine firmware opens the door to precise control of the printheads. The key tool here is waveform tuning — the shape of the electrical pulse that drives the piezo element in the printhead.

The waveform governs everything: how a droplet is formed, with what force it is ejected, at what angle it travels, and how it behaves upon impact. Adjusting its characteristics influences droplet size, velocity, and landing behavior. This is a fundamental optimization tool, completely unavailable in standard machine operation — and therefore so valuable.

Waveform control allows adaptation of droplet dynamics to the characteristics of a specific ink. Custom ink formulations differ from standard factory inks in viscosity, surface tension, and drying time. Without waveform adjustment, achieving optimal print quality with non-standard inks would be nearly impossible.

Precise control also improves adhesion. Different printing speeds and substrates require different droplet impact energies. Too much energy causes splashing and deformation, too little results in weak adhesion and easy abrasion. Tailoring these parameters ensures stable, durable printing under any conditions.

Another benefit is the reduction of satellites — tiny unwanted droplets accompanying the main droplet during ejection. This phenomenon, known as misting, is a significant issue: it reduces print quality, creates ink fog around the design, and systematically contaminates the machine interior. Proper waveform configuration minimizes or eliminates satellites, ensuring clean, precise prints.

What do we gain through adaptation?

The result is a machine operating at performance levels impossible to reach in standard configuration. Ink adhesion, environmental resistance — humidity, moisture, temperature fluctuations — and color consistency exceed factory capabilities.

This is not about better aesthetics. It’s about functionality. A membrane keyboard must withstand years of intensive industrial use. The print cannot fade or wear, colors must remain stable, and the structure must resist chemical cleaning. A standard machine cannot guarantee this.

An additional benefit is extended printhead lifespan. Optimal piezo operation under properly tuned waveforms reduces mechanical wear. Printheads — the most expensive consumables — last longer without losing performance.

Why modify machines?

Machine adaptation is not technological whim but business strategy. Full control over the production process means independence from machine manufacturers, service providers, and standard solutions. When a problem arises, no external support is needed — everything is solved internally, quickly, on our own terms.

This autonomy becomes a competitive advantage. While others adjust their products to the limitations of standard machines, a plant with a customized machine can design products without technological constraints. If a customer needs an unusual solution — a special substrate, specific resistance parameters, unique colors — an adapted machine makes it possible.

The process of adapting digital printing machines shows that in high-precision industry, standard solutions are often only the starting point. The real value emerges when the technology is tailored to specific production requirements.