Printing on Plastic Parts – The Difference Between Pad Printing and Screen Printing
Printing on thermoformed plastic parts enables detailed lettering, designs, and branding elements. Pad and screen printing are the most commonly used methods, depending on the application. This article explores these techniques in more detail.
Sarah Guaglianone
Updated on June 2, 2026
Share
Contents
Screen printing vs. pad printing – the key points at a glance
Plastic parts can be printed as part of the surface finishing process using screen printing (for flat surfaces) or pad printing (for uneven surfaces).
Screen printing offers high colour intensity and is ideal for large print runs, whilst pad printing allows for finer details on complex surfaces.
The choice of printing method depends on the shape of the part, the print size and the desired level of detail.
→ Select the appropriate printing method in our configurator
In what situations are plastic parts printed?
Printing on plastic parts is a form of ‘off-mould decoration’ and is carried out after the moulding process. This is particularly common for products such as covers,trays and housings produced by plastic thermoforming , printing on plastics is an ideal solution for customising the appearance of thermoformed parts.
What printing options are available?
Printing allows for the customisation of thermoformed parts and enhances their visual appeal. Logos, scales or control elements can be integrated directly, giving the thermoformed part a professional, brand-specific appearance.
Choosing the right printing method: Requirements for the print
The print must be durable and scratch-resistant to ensure that the surfaces remain long-lasting even with heavy use. Choosing the right printing process is therefore important to ensure high quality, durability and a striking visual impact.
Printing on plastic parts is therefore possible with many thermoplastics; however, it is important to note that not all plastics are equally suitable for printing. Some plastics have a naturally low surface tension, which can make it difficult for the ink to adhere.
In such cases, it is advisable to carry out specific pre-treatment processes, such as cleaning, degreasing or the use of bonding agents, in order to improve the adhesion of the paints.
A comparison of printing methods: screen printing and pad printing
Two of the most common methods used for printing on plastic parts are screen printing and pad printing. Both printing processes have specific characteristics and are suitable for different applications. The following sections will help you decide whether screen printing or pad printing is the better choice for you.
Screen printing on plastic – ideal for flat surfaces
Screen printing on plastic is particularly effective on flat surfaces and is frequently used on larger areas such as covers and casings, as the slightly coarse fabric texture limits the ability to reproduce very fine or small screen-printed designs with precision.
Screen printing process
What is screen printing?
Screen printing is a type of transfer printing and is based on a stencil principle that allows designs to be transferred very precisely onto a variety of surfaces. The screen printing process is also known as stencil printing because certain areas of the screen are covered by a stencil, so that the ink only passes through the open areas of the mesh onto the material.
How does screen printing work?
Preparing the screen: A screen made of a fine-mesh fabric (usually polyester or polyamide) is stretched over a screen printing frame. A photosensitive coating is applied to this screen, which, after exposure, reproduces the desired screen-printed design.
Creating the stencil: The design to be printed is transferred onto the screen by exposing the photosensitive layer using an exposure unit. Areas that are not exposed remain permeable to the ink, whilst the exposed areas block the ink.
Printing process: In screen printing, the screen is placed on top of the plastic to be printed. A squeegee (a rubber blade) is used to pull the ink across the screen. The ink is forced through the open areas of the screen onto the material, creating the design.
Drying: After printing, the printed material is dried to set the ink. This can be done by air-drying or in special drying units.
Advantages and disadvantages of screen printing
Here is a list of the main advantages and disadvantages of screen printing:
Screen Printing Advantages
Screen Printing Disadvantages
High color intensity: Vibrant colors on dark materials.
Complex preparation: Time-consuming and costly.
Durability: Resistant to abrasion and weather conditions.
Limited detail accuracy: Fine details can be difficult to reproduce.
Special colors & effects: Metallic, fluorescent inks possible.
Time-consuming multi-color printing: Each color requires a separate pass.
High reproducibility: Ideal for large print runs.
Limited flexibility: Expensive design changes.
Pad Printing on Plastic – Ideal for Uneven and Complex Surfaces
Pad printing is a versatile and highly flexible printing process that is particularly well suited to printing on uneven and complex surfaces.
What is pad printing?
Pad printing is an indirect printing process in which a flexible pad is used as a transfer element to apply ink to the desired material.
Pad Printing
How Does Pad Printing Work?
Ink Transfer: Ink is applied to an engraved printing plate (cliché).
Ink Pickup: A silicone pad picks up the ink from the engraving.
Printing Process: The pad presses the ink onto the plastic part.
Adaptation to Shape: The flexible pad conforms to curved, concave, or convex surfaces.
Advantages and Disadvantages of Pad Printing
Pad Printing Advantages
Pad Printing Disadvantages
Flexible for complex shapes: Suitable for curved and irregular objects.
Limited print size: More suitable for smaller areas.
Fine lines and detailed motifs: Precise reproduction of small and intricate designs.
Thinner ink layer: Less intense color compared to screen printing.
High durability: Resistant to abrasion, chemicals, and external influences.
/
Efficiency: Multi-color prints possible in one step.
/
Quick drying: Inks dry quickly at room temperature.
/
Pad Printing vs. Screen Printing – Applications at a Glance
If you want to print on plastic parts, the main difference between pad printing and screen printing lies in their respective applications and the types of surfaces that can be printed on.
Pad printing for irregularly shaped and complex parts
Thermoformed plastic parts for the automotive industry: switches, buttons and controls in the vehicle interior, such as controls for air conditioning systems or radio buttons. Such parts often have curved or uneven surfaces, which can be printed on with precision using pad printing.
Thermoformed plastic parts for the medical sector: Pad printing is used on medical device housings that are small and have complex shapes, such as the casings of inhalers and dialysis machines.
Plastic enclosures for electronics: Large enclosure components, such as those used in household appliances, computers or consumer electronics.
Large-format cladding: Components used in sectors such as the automotive industry, including caravan covers and tractor covers.
The choice between pad printing and screen printing therefore depends on the shape of the thermoformed part, the desired print quality and the intended use.
Printing on plastic parts using screen printing or pad printing – A summary
So which is better – pad printing or screen printing? When comparing the two printing methods, pad printing stands out as the best option for printing on uneven and complex surfaces. This also makes it possible to print highly detailed designs, albeit in a smaller size and with lower colour intensity.
Screen printing is particularly suitable for large, flat surfaces and produces very vibrant colours. However, it is significantly more labour-intensive than pad printing, and intricate designs are rather difficult to reproduce due to the coarse texture of the fabric. If you are unsure whether to choose pad printing or screen printing for your project, please contact us. We’ll be happy to help.
Frequently Asked Questions About Screen Printing and Pad Printing
Screen printing (for flat surfaces) and pad printing (for uneven surfaces) are suitable options for printing on plastic parts. Both have their advantages, depending on the shape and detail requirements.
Screen printing offers high color intensity, is durable, and is well-suited for large print runs. However, it is labor-intensive and less precise when it comes to small details.
Pad printing is ideal for complex or curved surfaces and allows for fine details on small areas. It is flexible and fast, but produces less vibrant colors.
Screen printing is better suited for large, flat surfaces with bold colors. Pad printing is ideal for complex shapes and fine details. Both methods have their strengths, depending on your needs.
Checking CAD Models for Thermoformability: The Designer's Guide
Whether a plastic part is thermoformable is determined in the CAD model. Anyone who discusses geometry, wall thicknesses, and demoldability only after the first sampling pays for this loop with tool modifications, material waste, and lost weeks in the project timeline. This can be avoided during design: with a structured check that evaluates each model along this guide and makes typical sources of error visible early on.
Thermoformed Parts in Practice
Design for Manufacturing (DfM): Guide to Manufacturing-Oriented Design
With the new Design for Manufacturing analysis from formary, it is now possible to check CAD data for thermoformability in a matter of seconds, allowing potential sources of error to be identified early on before they become costly. Read on to find out what features the DfM software offers and what the Design for Manufacturing principle entails.
Thermoformed Parts in Practice
Unit Costs and Tooling Costs in Thermoforming: Cost Factors and Scalability
The costs in plastic thermoforming are a crucial factor for the economic efficiency and planning of a project. They depend on various influences along the process chain and change depending on production volume and requirements. This article explains how costs in plastic thermoforming are composed, how they develop with increasing quantities and when the process becomes particularly worthwhile.
Thermoformed Parts in Practice
Guide: Top 5 Tips for Cost Reduction in Thermoforming
Costs in plastic thermoforming are primarily determined by design, material selection, and tooling design. Many cost drivers are not immediately apparent and often only become visible late in the development process. This is precisely where unnecessary costs frequently arise, costs that can be avoided with the right measures.
Thermoformed Parts in Practice
Thermoformed Plastic Parts in Use – Detailed Applications
Thermoformed plastic parts play a crucial role in almost every industry, from manufacturing and mechanical engineering to medicine and food production. In this article, we take a closer look at the various applications of thermoformed plastic parts across different industries.
Thermoformed Parts in Practice
What Is a Workpiece Carrier? Definition & Applications
A constant challenge in the manufacturing industry is efficiently managing material flow throughout all assembly stages and departments. These logistical challenges can be optimally addressed by using product-specific workpiece carriers. Learn more in this article.
Thermoformed Parts in Practice
Checklist: 10 Details a plastic thermoformer needs from you
You’re planning to source plastic thermoformed parts and want to submit a request for a quote. But what information does a thermoforming supplier really need to provide you with a meaningful quote? Incomplete requests lead to follow-up questions, delay the quoting process, and complicate the technical evaluation. If you provide the right information from the start, you’ll receive a reliable estimate faster and avoid unnecessary back-and-forth.
Platform & Features
Platforms for Customized Plastic Thermoformed Parts Compared: Which is Suitable for Your Application?
This comparison shows which platforms are suitable for sourcing customized thermoformed parts, how their models differ, and when a specialized solution makes more sense than a generalist manufacturing platform or traditional direct procurement.
Platform & Features
Ordering Standard Plastic Thermoformed Inserts: Step by Step for the formary Online Shop
Standard plastic thermoformed inserts are suitable for companies that want to equip SLCs or Euro containers quickly, without tooling costs and starting from small quantities. The formary Online Shop offers 220 ready-made inserts, including standard versions made from white PS and ESD-resistant versions made from conductive black PS. In this article, we show you step by step how to find suitable standard thermoformed inserts in the formary Online Shop, check technical details, request a sample and then obtain a quotation.
