In the world of industrial printing, viscosity has long been an invisible ceiling. For decades, conventional inkjet printheads have been confined to low-viscosity fluids – materials with a viscosity typically below 20 MPas. This limitation has largely relegated digital printing to the world of graphics, signage and decorative layers.
Technology
THE VISCOSITY BREAKTHROUGH – DIGITALLY PRINTING PVC COATINGS
Company
Quantica
Ben Hartkopp from Quantica, describes the ways in which high-viscosity materials are revolutionising digitally printed PVC coatings
Two NovoJet printheads inside a production demonstrator unit
Two NovoJet printheads inside a production demonstrator unit
NOVOJET TECHNOLOGY
Quantica is breaking that ceiling. Its patented NovoJet technology jets materials up to 250 MPas at jetting temperature. Through heating and shear thinning, this translates to significantly higher viscosities, with the printhead having jetted Newtonian fluids near 15,000 MPas (measured at room temperature). This capability is driving a shift in inkjet – from digital graphics towards industrial production environments.
While Quantica’s technology is already being used by research institutes and R&D laboratories for application research and development, the focus is now moving to the factory floor. The technology is centred around the introduction of the Print Engine. This is a production-ready system that integrates
high-viscosity printheads with a robust fluid management and curing system required for specialised, round the clock manufacturing.
NovoJet printheads jetting high-viscosity materials
NovoJet printheads jetting high-viscosity materials
THE FIRST APPLICATION
The first major application for the Quantica Print Engine targets the €11.63 billion (2025) PVC window profile market. This is a high-volume industry defined by a variety of frames, shapes and designs. Traditionally, these profiles are coated using foil lamination – a process currently used across an estimated 2,000 production lines globally.
FOIL LAMINATION DISADVANTAGES
Despite being the industry standard, foil lamination is plagued by hidden costs and operational friction:
Material Waste – Actual waste rates can reach up to 25% (versus the ~5% often claimed) due to scraps and expired inventory.
Production Inefficiency – Lines suffer 60–70% downtime due to changeovers, which can take anywhere from 30 minutes to eight hours.
Labour and Quality – A traditional line requires 3–5 operators, yet quality issues are often not discovered for 24–72 hours due to curing delays.
Overall, foil lamination is a highly analogue process that does not allow for quick changes or customisation.
A COMPLETELY DIGITAL SOLUTION
Inkjet technology is already established for the graphics portion of PVC window profiles. The current ink-jettable protective topcoat offers no substantial benefit compared to foiling. However, the introduction of The Quantica Print Engine enables the first completely digital workflow by applying the protective topcoat. By moving the final functional layer from a physical foil to a jetted fluid, manufacturers can now offer total customisation across any frame shape or design, without stopping the line.
A rendering of what the system could look like in a production environment
A rendering of what the system could look like in a production environment
PERFORMANCE AND DURABILITY
The breakthrough lies not only in the process, but in the material performance. While ink-jettable topcoats currently exist, they generally cannot match the quality or scratch resistance of foil lamination. Leveraging NovoJet technology and its ability to handle high-viscosity, particle-loaded fluids, Quantica provides the final puzzle piece in a completely digital solution. The system fills the existing gap by jetting a high-quality, PVC-compatible protective coating in a single pass, targeting a precise layer height of 20–30 microns.
“Foil lamination is plagued by hidden costs and operational friction”
Window profiles can come in thousands of shapes, sizes and designs
Window profiles can come in thousands of shapes, sizes and designs
HIGH VISCOSITY BENEFITS
Quantica has begun active development on this application alongside its materials and integration partners. Results exceed traditional standards:
Scratch Resistance – While traditional foils offer 12–14N resistance, the current samples deliver 16N. The company is currently targeting 30N through the inclusion of specialised particles that were previously unjettable.
Enhanced Longevity – High-viscosity formulations allow for significantly higher UV-blocking concentrations, extending the lifespan of outdoor profiles and protecting the manufacturer’s investment.
Economic Impact – Beyond material savings, the ability to verify quality immediately and eliminate the inventory burden of physical foils, represents a massive reduction in overheads.
This print sample demonstrates Quantica’s initial tests – a PVC substrate featuring an ink-jetted wood pattern finished with a glossy, protective topcoat applied by the NovoJet printhead
This print sample demonstrates Quantica’s initial tests – a PVC substrate featuring an ink-jetted wood pattern finished with a glossy, protective topcoat applied by the NovoJet printhead
CONCLUSION
The transition is already in motion. Quantica is currently collaborating with specialised integration and materials partners to ensure the Print Engine seamlessly integrates into existing industrial lines. By unlocking high-viscosity materials, Quantica is not just improving a printing process, it is redefining the economics and footprint of manufacturing.
NovoJet is a Trademark of Quantica