Packed with valuable content! The current development of pre-press laser engraving technology, explained thoroughly in one article!
Laser engraving
The technical level has improved, but it needs to be verified
If prepress software determines the "upper limit of the data level", then laser engraving and subsequent plate-making systems determine whether these data can be stably and repeatably transformed into graphic structures on printing plates. In flexographic plate-making technology in 2025, laser imaging and exposure will still be the most technically dense part.
At present, the main problem restricting high-end flexo printing is that there is still a gap between the high-gloss and field printing performance of flexographic and gravure printing, especially the low field density, which is still a big challenge faced by flexographic plates. At the theoretical level, improving the resolution of on-site screening means that the printing plate can carry more ink to the substrate, thereby further increasing the ink density of on-site printing and improving the uniformity of ink coverage. However, the difficulty of realizing screen technology, in addition to the front-end algorithm, is mainly in laser engraving and subsequent plate making, and laser engraving is the most difficult obstacle to overcome.
The progress of laser engraving technology in 2025 will mainly come from ESKO and XSYS in Europe, in addition, China's domestic engraving machine manufacturer - ASKAI has also made significant progress.
01
Quartz laser imaging technology
An important upgrade after Crystal laser imaging technology
At the 2024 Drupa exhibition in Germany, ESKO officially unveiled Quartz laser imaging technology. The word "Quartz" is derived from the English quartz (quartz), and it is reasonable to guess from the name itself that this technology uses a large number of high-grade quartz materials in optical systems. High-end quartz optics are an important foundation for achieving high transmittance, low scattering, low distortion, and resistance to high energy density transmission of laser beams, ensuring that the laser can reach the imaging target in a stable and controlled state, thereby avoiding energy loss, spot distortion, or material surface damage.
Although Quartz laser imaging technology has been publicly unveiled in 2024, from a practical application perspective, it will not enter the user implementation stage until 2025. At the same time, ESKO will also launch a small-format Quartz laser engraving machine specifically for label printing applications in 2025, and display a series of printing proofs to strengthen the technology's positioning in high-precision, small-format application scenarios.
Figure 8 ESKO offers Cyrstal XPS 4835 Quartz for label printing
From the perspective of technical system, Quartz laser imaging technology is not a single hardware upgrade, but a software and hardware synchronous upgrade solution carried out by ESKO in the process of adding screen and laser engraving. Compared with the previous generation of Crystal laser imaging technology, Quartz laser imaging technology has achieved a significant improvement in the ability to add micro cavities and screens, especially in the control of field microstructures, effectively improving and eliminating the common dark line problems in Crystal laser imaging systems. This improvement has direct significance for improving the uniformity of on-site printing.
Focusing on the Quartz laser imaging system, ESKO has simultaneously launched two dedicated mesh solutions (Quartz VQ and Quartz SQ, which have been described above). The mesh solution supported by the Quartz imaging system is obviously benchmarked against the Belissima network system in Hamillroad, UK, and its overall technical route can be classified as the third-generation frequency modulation network solution, emphasizing the simultaneous improvement of microstructure stability and visual resolution ability.
It should be emphasized that although Quartz laser imaging technology has made positive progress at the level of technical ideas and experimental samples, the types of printing plates it can support are still limited, and the full test cycle is relatively long. In high-end thin-film printing and other applications with more demanding requirements for stability, printability, and ink transfer, whether Quartz laser imaging technology can achieve further breakthroughs still depends on more large-scale printing verification based on real-world production conditions.
02
Thermoflex Edge laser engraver
Benchmark the Quartz laser engraver against the competition
XSYS released the introduction of its latest engraving machine, the Thermoflex Edge, in the fourth quarter of 2025 and called it the third-generation laser engraving equipment, but it did not run on-site and did not provide printed proofs when it appeared at Eurostandard 2025. From the current official publicity, it can be seen that the imaging resolution of the Thermoflex Edge laser engraver supports 2400 dpi and 2540 dpi, and is compatible with Woodpecker Nano mesh technology. At this resolution, the device can generate a higher-precision micro-cavity mesh structure to improve the density of solid ink and gradient quality. In terms of imaging efficiency, the rated speed of the device is 8.5 m²/h, which is a certain improvement over existing similar equipment.
The software architecture of the Thermoflex Edge laser engraver is designed with an open architecture that allows it to interface with a variety of existing workflow systems, and XSYS claims that it can use almost all common output files, including ESKO's Len file format, which reduces the difficulty of system integration. At the same time, the Thermoflex Edge laser engraver also introduces EcoFillX software to reduce solvent consumption.
Figure 9 Thermoflex Edge laser engraver
In terms of human-machine interaction, the Thermoflex Edge laser engraver is equipped with an updated user interface and offers modular automation options to reduce manual handling and handling steps. This design reduces operational errors and improves equipment utilization. In addition, remote service capabilities are integrated to improve the serviceability and operational life of the equipment in the production environment.
In summary, the technical characteristics of the Thermoflex Edge laser engraver are mainly focused on three aspects: first, high-resolution imaging capabilities (2400/2540 dpi, supporting high-level micro-cavity and network technology); second, efficiency optimization (8.5 m²/h capacity, EcoFillX reduces solvent consumption and energy consumption); third, system compatibility and operational improvements (open architecture, thick version adaptation, automation interface).
Enxis's micro-cavity plus network technology Woodpecker has not been launched for a short time, but from the actual usage point of view, it has not broken through the micro-cavity effect of ESKO's Crystal XPS, so from the perspective of installed capacity at home and abroad, it is still relatively large compared with ESKO.
03
Xpose! 330 inner drum laser engraver
A conventional flexible version of the laser exposure machine can be used
Headquartered in Switzerland, Lüscher Technologies AG has long focused on the development of high-precision laser imaging and exposure systems, covering flexo, offset, screen printing, and printed circuit boards (PCBs) and other applications. In the field of flexographic plate making, Lüscher has launched laser engraving equipment for engraving black film for many years, and its technical route is significantly different from the current mainstream external drum laser engraving system.
Lüscher has always used inner drum laser engraving technology. Under this technical architecture, the printing plate or imaging material is fixed inside the inner drum, and the scanning and imaging are completed by a high-speed rotating mirror with a single laser. The main advantages of this technical route are reflected in two aspects: first, the imaging quality is high, and the inner drum structure has inherent advantages in terms of mechanical stability and optical path consistency, making it easier to achieve higher imaging resolution and better point shape consistency; second, there is no need for plate mounting, and the imaging material is directly fixed in the inner drum, eliminating the need for mounting and positioning in the outer drum or flat panel system, which can significantly reduce the complexity of operation, especially in small plate making scenarios.
At the same time, there are obvious engineering limitations in internal drum laser engraving technology: first, the equipment manufacturing is difficult, and the high-speed rotation system and high-precision optical components put forward higher requirements for manufacturing and assembly; second, the cost of equipment is high, affected by structural complexity and manufacturing accuracy, and the price of such equipment is usually high; third, the market acceptance is limited, in the field of flexo-printing, the installed capacity of internal drum equipment is low for a long time, and the user scale is relatively limited.
For the above reasons, although the internal drum laser engraving technology has great advantages in terms of imaging quality, it has not become the mainstream route of flexible laser engraving equipment.
In 2025, Lüscher launched the Xpose!330 internal drum laser engraver, further expanding its technological layout in the field of flexographic. A notable feature of this device is its support for three different types of laser configurations. Among them, the 380nm UV laser head can be directly used for the exposure of traditional flexographic plates, a technical route that bears clear similarities with CTCP (Computer To Conventional Plate) technology in the field of offset printing.
Figure 10 Lüscher Xpose!330 Internal Drum Laser Engraving Machine
The main engineering advantage of this solution is that users can continue to use the traditional flexographic plate-making process without the need for film, thereby simplifying the plate-making process to some extent and reducing dependence on consumables. At the same time, for users who need to engrave black films, the Xpose!330 device also supports configuring a laser head suitable for black film engraving, giving the equipment a certain degree of flexibility in application.
Overall, Lüscher's adherence to internal drum laser imaging technology in the field of flexographic plate making represents a technology choice that prioritizes imaging quality but involves significant trade-offs in terms of cost and large-scale application. Its latest equipment offers a diversified attempt in laser configuration, providing new possibilities for traditional flexographic plate-making and film-free processes, but its prospects in the large-scale flexographic plate market still need to be further observed in terms of cost, efficiency, and user acceptance.
04
Vulcan 4835 Laser Engraving Machine
High-end breakthroughs of domestic laser engraving machines
ISCAN is a well-known domestic laser engraving machine manufacturer. The recently launched Vulcan engraving machine adopts an integrated high-power fiber laser source with a 256-channel independently modulated parallel system, capable of multi-beam synchronized engraving. The system has a maximum laser output power of approximately 300W, and under 4000 dpi resolution, it can complete full-dot engraving of a 50×80 inch flexographic plate in about 26 minutes.
Figure 11: Escaik's 10160 dpi Vulcan 4835 Laser Engraving Machine
The light valve array combined with a high-magnification imaging optical system forms a square laser output structure. Under the 4000 dpi condition, the minimum resolvable line width in the horizontal and vertical directions is approximately 6.35 μm, with an accuracy for diagonal and curved lines of about 15 μm, achieving single-pixel level precise imaging control. The device supports expansion with higher-density light valve modules, reaching a maximum engraving resolution of 10160 dpi, corresponding to a laser spot size of 2.5 μm × 2.5 μm, which can be used for high-precision processing of microstructures below 5 μm. At the same time, a variable resolution modulation mechanism is introduced, allowing continuous adjustment of circumferential resolution within the range of 2400–10160 dpi to adapt to grating structures and three-dimensional microstructure plate-making processes.
The system integrates laser ranging and voice coil motor dynamic focusing control technology, enabling real-time acquisition of surface height changes of the plate material during laser scanning and focus compensation, effectively reducing defocusing errors caused by material thickness fluctuations and surface unevenness. In addition, through multi-pass overlapping scan strategies, real-time laser energy calibration, and temperature monitoring modules, the stability, consistency, and imaging repeatability of high-density graphic engraving processes can be improved.
Chinese domestically produced flexographic engraving machines long used 830 nm lasers commonly employed in offset CTP, which resulted in significant gaps in efficiency and engraving quality compared to leading international models. Escaik's efforts have narrowed this gap, and for the fields of labels, pre-printed and post-printed carton plate-making, it can even provide a local alternative to imported equipment.