Creating a Mask File in Adobe Illustrator for the MGI JetVarnish 3DS UV and IFOIL

What is a Mask? Mask files are black and white files that show where to apply special finishes, like varnish and foil. They are separate from your colored artwork file, but art files and varnish/foil mask files work together to create your project. Files matching the sheet size and number up of the printed sheet are necessary to obtain the best registration possible. Foil and varnish jobs require mask files with your CMYK artwork. One mask file is required showing where varnish will be applied. A second mask file is required showing where foil will be applied. If multiple colors of foil will be used on the project, one mask file for each foil color is required. Any black areas on the varnish or foil mask file(s) should be set to 100% black (K) and the rest of the page should be white. This will ensure the best varnish coverage. Mask files should be created from your CMYK file. You should start with your art file which should contain all art being printed, varnished and/or foiled on one layer. Again, this file should mimic the sheet size and number up of the printed sheet. Save this as a high resolution pdf file called “Art file”. Then, go back to your CMYK art later and create a duplicate later called “Print”. Remove everything from this layer except what will be printed and save it as a high resolution pdf file called “Print file”. Again, go back to your CMYK art layer and create a duplicate layer called “Varnish. Remove everything other than areas which will have varnish and save it as a high resolution pdf file called “Varnish file”. Again, go back to your CMYK art layer and create a duplicate layer called “Foil”, then remove everything other than the areas which will have foil. Save this layer as a high resolution pdf file called “XXXXX Foil file with “XXXXX represent the color foil, i.e. “Green Foil file). Repeat this last step if you have multiple foil colors, starting with the CMYK art later, create one duplicate layer for each foil color and delete everything other than what will have that color foil. For example, for a job with varnish and 2 foil colors (blue and green), you will have 4 files total. First file will contain only artwork that will be printed and this file will be named “Print file.pdf”. Second file will contain only areas to be varnished and these areas should be in 100% black. This file will be named “Varnish file.pdf”. The third file will contain only areas where blue foil will go and these areas should be in 100% black (K). This file will be named “Blue foil file.pdf”. The fourth file will contain only areas where green foil will go and these areas should be in 100% black (K). This file will be named “Green foil file.pdf”.

This is the art file (CMYK) which has the background printing, varnish areas and two color (blue and green) foil areas all on one layer. When you expand the layer window you will see there is the printed background (layer called “Print file”), the yellow flowers which will have varnish (layer called “Varnish”), the blue flowers which will have blue foil (layer called “Blue Foil”) and the green flowers which will have green foil (layer called “Green Foil”). This file should be saved as a high resolution pdf called “Art file”.

The 1-up art file is on a 13 X 19 artboard The 1-up art file is on a 13 X 19 artboard. This mimics the sheet size and number up that will be printed. This is the art file (CMYK) which has the background printing (crop marks included), varnish area and two color foil areas all on one layer. When you expand the layer window you will see there is the printed background (layer called “Print”), the yellow flowers which will have varnish (layer called “Varnish”), the blue flowers which will have blue foil (layer called “Blue Foil”) and the green flowers which will have green foil (layer called “Green Foil”). This file should be saved as a high resolution pdf called “Art file”.

Within your art file, create a duplicate later called “Print”. Remove everything from this layer except what will be printed and save it as a high resolution pdf file named “Print file”.

Go back to your art file, create a duplicate later called “Varnish”. Remove everything from this layer except what will be varnished.

Select each item on page and set to 100% black (K) Select each item on page and set to 100% black (K). Repeat until all items are in 100% black. Save this file as a high resolution pdf named “Varnish file.pdf”

Go back to your art file, create a duplicate later called “Blue foil”. Remove everything from this layer except what will be in blue foil.

Select each item on page and set to 100% black (K) Select each item on page and set to 100% black (K). Repeat until all items are in 100% black. Save this file as a high resolution pdf named “Blue foil file.pdf”

Remove everything from this layer except what will be in green foil. Go back to your art file, create a duplicate later called “Green foil”. Remove everything from this layer except what will be in green foil.

Save this file as a high resolution pdf named “Green foil file.pdf” Select each item on page and set to 100% black (K). Repeat until all items are in 100% black. Save this file as a high resolution pdf named “Green foil file.pdf”

You now have a total of 4 files created from your original art file: 1) Print file.pdf 2) Varnish file.pdf 3) Blue foil.pdf 4) Green foil.pdf You should zip these files and send them to C & T for your project. If the zipped file is too big to email to C & T, you can send them a path to your FTP server or other file transfer software (i.e., Dropbox, etc.)

too thin..won’t hold varnish/foil Best Practices for Creating Ideal Quality Mask Files When creating masks, alignment is the most critical part of the process. Make sure your mask files are created from your original art file, which is in position and on the same sheet size and number up as the printed sheets you are sending. Because foil differs in application from ink and occurs after the printing process, it shouldn’t be extremely small and thin. Stay away from delicate graphics or thin/small fonts and lines (see example below). The minimum font size is 10pt for regular fonts, 12pt for bold or fonts with thick strokes. Mask files must be vector and created in a program like Illustrator or InDesign. Do not include special effects like gradients, blurs or shadows on your mask, and only use 100% black to indicate where you want the raised foil and varnish to appear. Any gradients or fading on fonts/images will result in unclear borders and the inability for foil to stick to those areas that are less than 100% black. If die cutting will take place on an area that has UV and/or foil, we recommend creating a channel where the job will be cut. This will reduce the chance of cracking the UV/foil when die cutting. Note: Unlike traditional UV flood coat applications, we do not recommend any solid coverage areas larger then 6 x 6 for Foil or Varnish. Some lines too thin..won’t hold varnish/foil *You do not need any special application to create a Mask file. All art and Mask(s) can be created in Adobe Suite.