By Melissa Donovan
Smaller format flatbeds, which for the purpose of this article max out at approximately 50 inches in width, allow print shops to diversify beyond traditional signage into more profitable niches like complaint ADA/braille signage. This application is a logical extension of work already done in house. It naturally builds on existing in-house capabilities, making it a practical and profitable alternative to outsourcing.
Thanks to Improvements
Advancements to smaller format flatbed printers in the last few years make ADA/braille signage for offices, medical buildings, and more a feasible offering for any print service provider (PSP). Improvements in the ink, software, and hardware make the difference.
According to Kevin Currier, marketing director, Direct Color Systems, ink improvements are one development that make ADA/braille possible on flatbed UV printers. “Braille signage has specific requirements for outdoor durability, which can be hard to achieve with many ink sets that are not specifically designed for the purpose.”
“In recent years, advancements have made it both technically and economically feasible for smaller format UV flatbed printers to produce ADA/braille signage. This includes ink formulations capable of quickly building up the height needed for standardized braille dots using layers of white ink and clear varnish,” shares Mike Pruitt, product manager, Professional Imaging, Epson America, Inc.
Sandi Baginski, creative director, Innovative Digital Systems, finds the ability of smaller format flatbeds to provide multi-layer ink builds in a single pass a game changer. “This simplifies the previously tedious process of layering ink to create raised textures and tactile surfaces—such as braille dots.”
Front end software also plays a role. “Many print systems are able to create layers, which is necessary for braille but braille requirements require tight control over the build height, the surface of the top layer, as well as the shape of the dots and pictograms,” shares Currier.
According to Emilio Rangel, UV product manager, Mutoh America, Inc., the secret recipe for long-term success in producing ADA signage in house is the right ink and workflow/software. Improvements in both lead to PSPs meeting compliance standards efficiently and economically, something that once required outsourcing or specialized equipment.
Hardware developments include precise printhead technology that ensures highly accurate dot placement, adds Pruitt.
“Some of the most recent advancements in printhead and ink manufacturing allow for far greater Z-axis clearance than ever seen before; the increased distance between the printheads and substrate create the necessary space for an accurate, ADA-compliant tactile build,” cites Baginski.
Necessary Features
ADA/braille signage presents a very specific type of criteria.
Software must be able to generate braille constantly and correctly, notes Currier. Braille not only requires layering, but also the ability to control the thickness and number of layers to meet various regional specifications. “As an example, software that allows the user to type in normal text and have it be guided to compliancy regarding font style, size, kerning, and placement and then set the braille dots following language and regional requirements.”
To create the most compliant and efficient ADA/braille signage, it is best to source a printer that allows for easy multi-layer printing and variable dot capabilities; building a braille dot typically takes multiple passes of a varnish and/or white ink, so you will want a printer that can do this with ease, agrees Baginski.
When considering a small format flatbed printer to create ADA/braille signage, Pruitt recommends looking into printhead accuracy and ink technology. The printer should offer an exceptionally accurate printhead to ensure consistent dot placement and size.
“Accuracy and registration are vital in creating a compliant dot shape within ADA tolerances, meaning a variable drop size and precise calibration are a necessity,” confirms Baginski.
Automatic height adjustment is key. “The ability to build up ink to compliant braille height and then print graphics directly over the top without re-measuring or rescanning the material saves huge amounts of time,” shares Rangel.
Another consideration is the curing system. “An adjustable LED UV curing system will make or break any braille dot as the cure power must be fine tuned to ensure the tactile areas reach the proper height without collapse and maintain integrity over time,” recommends Baginski.
It’s the Ink
Overwhelmingly, UV ink is the choice for braille/ADA signage.
Currier says at minimum it should be a UV ink designed for use on hard substrates, which maximizes adhesion. Additionally, if the flatbed system can print a primer or clear ink as a base or mixed into the ink that builds the height, adhesion is further optimized.
“A high-quality UV ink set is best suited for printing ADA/braille signage,” agrees Pruitt. “The majority of high-quality UV ink sets cure instantly, resulting in precise control over ink layering and height, enabling the printer and ink to work together to build the raised, durable dots required for ADA/braille signage.”
UV inks adhere to a variety of substrates—including acrylics, metal, and plastic—ensuring readability on a range of signage solutions, notes Pruitt.
Baginski points out the importance of durability. “A rigid and durable ink set improves the longevity of a sign, which must withstand repetitive physical contact, extensive cleaning, and potentially even outdoor conditions.”
“Hard ink is a must. Soft inks can compress under pressure, which is an immediate compliance issue. ADA signs are physically touched every day, so long-term durability matters. The right ink gives users confidence that their braille dots and raised elements will last without chipping or flattening over time,” notes Rangel.
New Service Benefits
Whether a PSP currently outsources ADA/braille signage and is considering bringing production in house or a print shop is adding ADA/braille signage as an entirely new offering—it’s often a lucrative investment.
“Bringing braille printing in house allows the PSP to gain more control over production, turnaround, and pricing. If currently outsourcing to another PSP or supplier doing digital braille, the savings are obvious. If you’re using a supplier who uses older, manual processes, the savings is even greater with the bonus of expanded creative possibilities,” notes Currier.
Those who outsource printing of ADA signage may not realize how the latest technologies have eased the production of braille signage. “This process was previously only possible with multi-step decoration methods, and we can now accomplish way more in a single pass through a digital printer,” says Baginski.
According to Pruitt, in addition to producing ADA/braille signage, these smaller format flatbeds print other applications including output on metal, plastic, and natural materials, as well as a range of promotional goods. This allows shops to expand offerings, reduce turnaround time, and gain control of quality and scheduling when compared to outsourcing.
“Integrating the production of braille signage within your own shop on a singular machine opens quite a few doors in terms of your digital offerings; not only will you quickly become an expert on producing ADA-compliant braille signage, but textured printing in any shape or form can easily become an added specialty service that pushes your product offering beyond limits,” agrees Baginski.
The return on investment (ROI) is quite high all things considered. If measuring ROI based on the purchase of the small format flatbed printer, Currier admits that braille signage is one of the best ROIs for a print system.
“Signage varies in size and complexity as well as substrates. In general, creating braille signage using a UV printer and the right ink and software makes the return higher. Production times are vastly improved; a system that can create a full bed of signs in a short period of time while unattended improves not only production of the signs but adds to the overall production of the shop. Signs can be loaded as pre-cut plates and printed or as one or more large sheets and post cut. The ability to meet those specific needs allows the print system to fit nicely into the existing workflow,” continues Currier.
Currier provides an example of an intermediate UV flatbed from Direct Color Systems that can produce a full bed of ADA compliant signs in less than one hour. At 6×8 inches, 18 signs are completed while unattended. That equates to around three minutes per sign with an ink cost of around $0.50 a piece.
Rangel believes that producing ADA signage in-house, rather than outsourcing it, is surprisingly inexpensive. He provides an example of a 6×4-inch room sign on digital acrylic, which costs under $2 to produce, while outsourcing that same sign can cost ten to fifteen times more. “Once production is brought in house, it quickly pays for itself, both in cost savings and turnaround time.”
Mutoh customers have paid off their small format flatbeds with a single ADA/braille job. This is especially true with large projects for hospitals, schools, or government facilities. One hospital purchased a Mutoh XpertJet 661UF for in-house ADA signage and saved over $200,000 in its first year by not outsourcing, according to Rangel.
“ADA/braille signage is a premium print method that can be sold at a much higher value than any standard sign, and the materials are the same. A slightly increased ink cost is the only difference between a simple sign and a fully tactile ADA-compliant braille sign, yet the profit comparison of each can be quite dramatically different,” adds Baginski.
In the Know
For PSPs unfamiliar with printing ADA/braille signage it is important to become knowledgeable with the regulations surrounding braille.
According to Baginski, familiarizing yourself with the ADA compliance and braille signage requirements is the biggest hurdle. “You need to fully understand and commit to what is needed from your sign to be an efficient braille communicator for those with a disability.”
“Braille can be complex as far as consistent compliance. There are variations in braille and knowing what is required can be daunting at the outset. From knowing whether to use Grade 1, Grade 2, or CA braille, to understanding placement and other installation guidelines, braille requires some specialized knowledge. With these requirements and standards, braille is a premium application that can be quite profitable,” suggests Currier.
In general, Pruitt says that for existing PSPs, the learning curve to understand ADA/braille signage production should be relatively short and easy to overcome. “I would plan for an hour or two of training, but a high-quality UV printer and the correct software should make the process seamless.”
The learning curve for ADA/braille signage is simplified with help from vendors. Mutoh developed tools like its StartRight Kit to guide new users through the entire ADA production process. Combined with Mutoh VerteLith RIP software, which includes built-in ADA print presets that automatically produce compliant braille height, new users go from zero experience to full production confidence very quickly.
Just Makes Sense
With today’s newest flatbed technologies, it is economically possible to offer ADA compliant signage in house.
“With a digital printer you have the added benefit of multi-color decoration to supplement design, increased value add, and versatility to print other goods increasing ROI compared to alternative and prior ADA/braille decoration methods,” summarizes Baginski.
Feb2026, Industrial Print Magazine
