The crack effect screen printing simulates natural aging or artificial distressing texture to give the product unique artistic value and functional characteristics. Its application scenarios cover cross-domain scenarios such as consumer electronics, industrial design, and cultural creativity. The following is an analysis from the perspectives of specific industries, typical products, and technology value-added:
I. Consumer electronics and smart hardware
1. High-end digital product decoration
Case: Retro style Bluetooth speakers, mechanical keyboards, game controllers
Effect:
Crack ink is printed on the surface of acrylic/metal shells, and UV curing temperature difference treatment (80℃→-10℃) is used to form an ice crack texture with a width of 0.1-0.3mm.
The crack density can be controlled at 15-25/cm², and the visual transition from fine to rough can be achieved by adjusting the ink thickness (0.08-0.15mm).
Technology value-added:
Improve product differentiation competitiveness (such as a brand of speaker crack model premium of 30%).
Meet users' needs for "industrial style" and "cyberpunk" design.
2. Surface treatment of wearable devices
Examples: smart watch straps, wireless headset charging boxes
Effects:
Screen-print crack ink on TPU/silicone material, combined with mechanical stretching (10%-15% strain) to induce directional crack expansion, forming imitation leather crack texture.
The crack width is 0.05-0.1mm, and the glossiness gradually changes from 15GU at a 60° angle to 3GU at the crack, simulating the texture of natural leather.
Technical value-added:
Reducing material costs (the cost of TPU+crack screen printing is only 1/5 of that of genuine leather materials).
Improve product anti-slip performance (crack surface friction coefficient μ≥0.6).
II. Automobile and vehicle interior
1. Imitation wood grain/stone grain decorative parts
Examples: high-end car center console, door panel, steering wheel decorative strips
Effects:
Screen-print two-component epoxy crack ink on PC/ABS substrate, combined with 120 mesh screen and mechanical engraving texture to form imitation natural wood grain crack.
The cracks extend along the wood grain direction, with adhesion reaching 6B grade (ASTM D3359), and can withstand 100 hot and cold cycles from -40℃ to 105℃ without cracking.
Technical value-added:
Replaces solid wood veneer (cost reduced by 40%), and reduces weight by 60%.
Achieve a realistic visual effect through crack depth (0.02-0.05mm) and color contrast (ΔE≤3).
2. Personalized accessories for motorcycles/bicycles
Case: fuel tank guard, frame decorative cover, helmet shell
Effect:
Screen-print UV crack ink on the surface of aluminum alloy/carbon fiber, combined with 80 mesh stainless steel screen and temperature difference treatment (90℃→-20℃), to form a rough industrial crack.
Crack width 0.2-0.5mm, density 8-12/cm², no corrosion in salt spray test (5% NaCl solution, 48 hours).
Technical value-added:
Meet riders' demand for "hardcore" and "retro" styles.
Improve product scratch resistance (pencil hardness ≥ 3H).
3. Cultural Creativity and Luxury Goods
1. High-end packaging and gift boxes
Case: Limited edition perfume, jewelry, and red wine gift boxes
Effect:
Screen-print water-based crack ink on cardboard/wood substrate, combined with sandblasting pretreatment (Ra=4μm) and hot stamping process, to form a contrast effect between ice cracks and metallic luster.
The crack width is 0.03-0.08mm, and the glossiness gradually changes from 20GU at a 60° angle to 5GU at the crack, passing the FDA food contact test.
Technical value-added:
Enhance the sense of ritual of unpacking (the unpacking rate of a certain brand of perfume crack gift box increased by 50%).
Reducing printing costs (the cost of screen printing crack process is only 1/3 of digital printing).
2. Artworks and cultural and creative derivatives
Case: antique picture frames, ceramic crackle glaze substitutes, cultural and creative notebooks
Effect:
Screen-print crackle ink on the surface of canvas/rice paper, combined with manual rubbing technology, to form a crackle texture imitating the Ge kiln of the Song Dynasty.
The crack density can be controlled at 5-15 lines/cm², and combined with the tea stain dyeing process, a "dated as old" visual effect is achieved.
Technical value-added:
Replacing traditional handmade crackle glaze (firing yield is only 60%), the silk-screen crack yield is more than 95%.
Shorten the production cycle (from 30 days of manual firing to 3 days of silk-screen + drying).
4. Industrial and architectural decoration field
1. Antique brick/cultural stone wall
Case: Wall decoration of museums, cafes, and theme hotels
Effect:
Screen-print crackle ink on ceramic/cement substrates, combined with 3D printing texture molds, to form cracks imitating natural stone.
Crack width 0.1-0.3mm, depth 0.05-0.1mm, acid and alkali resistance test (pH=2-12, no change in 24 hours).
Technical value-added:
Reduce material costs (the cost of antique bricks is only 1/8 of natural stone).
Improve construction efficiency (50㎡ can be laid in a single day, traditional stone is only 10㎡).
2. Outdoor signs and guidance systems
Case: scenic area signs, industrial park safety signs, retro style street lights
Effect:
Silk screen UV crack ink is printed on the surface of weather-resistant steel plates, combined with fluorocarbon paint primer to form a crack effect that is resistant to ultraviolet rays (QUV 340nm, no fading for 500 hours).
Crack width 0.08-0.15mm, density 10-20 lines/cm², impact resistance (IK10 grade).
Technical value-added:
Replace traditional corrosion processes (environmentally friendly and without chemical waste liquid).
Extend the service life of the logo (from 3 years to more than 8 years).
5. Application of functional crack screen printing
1. Flexible electronic sensors
Examples: wearable pressure sensors, flexible touch screens
Effects:
Screen-print conductive crack ink (silver nanowire content 5-8wt%) on PET/PI film to form a conductive crack network with a width of 0.1-0.2mm.
The crack resistance changes with pressure (0-100kPa, resistance change rate ≥50%), and the response time is ≤10ms.
Technical value-added:
Achieve large-area flexible sensing (such as pressure distribution monitoring of a certain brand of smart mattress).
Reducing sensor costs (the cost of screen printing process is only 1/10 of that of photolithography process).
2. Anti-counterfeiting and traceability identification
Examples: high-end wine anti-counterfeiting labels, pharmaceutical packaging
Effects:
Screen-print micro-crack ink (crack width 0.01-0.03mm) on optical films, combined with laser holographic technology, to form a non-replicable crack texture.
The crack pattern is scanned and identified by a mobile phone APP, and the anti-counterfeiting accuracy rate reaches 99.99%.
Technology value-added:
Replace traditional anti-counterfeiting codes (easy to copy).
Improve brand trust (the number of inquiries for anti-counterfeiting labels of a certain liquor brand increased by 300%).
6. Application Scenario Selection Guide
Application Scenario Recommended Ink Type Key Parameters Typical Cost (Yuan/㎡)
Digital Product Shell UV Curing Crack Ink Drying Speed ≤30 Seconds, Hardness ≥3H 80-120
Automotive Interior Parts Two-Component Epoxy Crack Ink Temperature Resistance -40℃ to 105℃, Adhesion Level 6B 150-200
High-end Packaging Water-based Crack Ink VOC≤1%, Pass FDA Test 60-100
Outdoor Signage Weather-resistant UV Crack Ink QUV 500 Hours No Fading, IK10 Impact Rating 120-180
Flexible Electronic Sensor Conductive Crack Ink Resistance Change Rate ≥50%, Response Time ≤10ms 300-500
7. Technology Trends and Future Outlook
Intelligent Crack Control
Use AI algorithm to simulate crack extension path, and combine digital inkjet technology to achieve personalized customization of cracks (such as facial contour cracks, brand LOGO cracks).
Environmentally friendly ink development
The application ratio of water-based UV crack ink (VOC≤1%) and bio-based resin (such as soybean oil modified acrylate) is increasing year by year, and it is expected that the market share will reach 40% in 2025.
Functionalized crack coating
Conductive particles (such as silver nanowires), color-changing microcapsules (such as temperature-changing/light-changing) or antibacterial agents are embedded in the cracks to achieve composite functions such as pressure sensing, anti-counterfeiting traceability, and antibacterial self-cleaning.
Through the collaborative innovation of material science, fluid mechanics and surface engineering, crack effect screen printing technology has developed from a traditional decorative process to a high-value-added technology with both aesthetics and functionality. In practical applications, it is necessary to comprehensively select ink systems, process parameters and post-processing solutions based on product performance requirements, production efficiency and cost targets to achieve the best expression of crack effects.