Work is progressing and I intend to post several photos soon. This post is a small update and some discussion about the screen-printing process and some things we have encountered along the way. I hope it helps and isn't too boring.
Update
With luck, the lowers will receive red, blue and purple Friday then get cleared and be ready for black. The image for the black lower is still being refined but is coming along.
We have all the color on the uppers except black and finally have an image for black that should work well. We plan to do black on the uppers by the end of the weekend and at that point the uppers will be done except for final layers of clearcoat.
I'd offer a few pictures now, but these things look far less than perfect until they get the black and it's going to be easier on everyone to see a progression of photos that show an end product.
How this works
Back in the day, playfield art was created by hand and images were done with drawings or simple photography methods. Each color layer had its own layout which was transferred to a black negative on acetate. That negative was used to transfer the image, via light-sensitive emulsion, onto a screen for printing. So, each color had its own screen, and they would stack up to create the entire image.
We still use part of that process today, the difference being images are fabricated in a computer and the acetate negative is printed with a wide format printer. To reproduce art, we use programs like Photoshop and Illustrator.
Photos of an original playfield are taken and entered into the programs, then each color layer is separated to create a layer (file) for that color. The layers are again stacked to provide the full image. This all sounds easy enough, and it is when you have pristine photos with obvious color separation like black and red. It becomes more complicated when you have images that are not complete (worn playfields) and colors that are so similar that the computer cannot separate them very well. For example, computers have a hard time separating dark purple from black. They do it, but it doesn't start out very well. It's labor intensive to sort through each color file and fix what the computer doesn't understand.
Sizing is also an issue. If the photo taken was exactly centered and perpendicular to the playfield, great. They never are. If it is off somewhat, the computer creates a file that is a parallelogram or whatever it likes. Then you get to play with converting raster images to x-y files and other fun stuff.
Once you have screens created for each color, it's a straightforward process to screen each color in turn and create the full image. The pitfalls are in sizing, alignment and color behaviors. Sizing is fairly obvious; each layer must be sized to match the playfield and the other colors. Alignment seems obvious but becomes complicated when manufacturing tolerances come into play. You might have noticed that many older games have inserts that are mismatched with the overlying art. They didn't have computer driven CNC machines in 1981. All these were cut by hand, with templates. You know the black circles around inserts? They exist to cover variations in manufacturing.
Color behaviors in screen printing is an interesting topic. It is not as straightforward as it seems. Since the colors are stacked, there is significant labor and cost involved and they always tried to minimize the number of colors used. Most playfields use a total of 6-8 colors and two of them have to be black and white.
Since the artist only had a few colors to use, they would combine their selected base colors to make an extra color. Blue on top of green can make turquoise, but to do that the blue must be somewhat transparent or it is applied with stippling (many fine dots). If you use transparent blue, it will affect all the blue on the board. If you use dots, there are limitations on what the screen can produce. This also applies to fading. If you use an airbrush, fading from red to orange to yellow is easy. Lay down a base of yellow, airbrush red and with a little practice you can cross the orange spectrum from solid red to no red (yellow base). Screen printing uses the same concept but has the limitation of how fine a dot you can produce on a screen.
Some of you have asked me about how we match colors to what the factory artist used. In this case we looked at original playfields (mostly faded, worn and dull), NOS and restored playfields (colors look good in person, harder to be exact with photos) and plastics (as worn and faded as the playfields). At the end of the day, it's an educated guess.
Actual color creation is the art of mixing base colors together. You've all seen it at Home Depot. Take a gallon of white, dump in some yellow and black, you get tan. On Solar Fire we used the Pantone system. A stack of swatches from which you can pick your color and it will tell you what base colors, and the percentage of those colors, are needed to create the desired color.
The paint world mostly uses base colors called "process colors". From a collection of about 16 process colors, you can create any hue imaginable. In order to simplify things, many artists will use at least some process colors as-is. The white, yellow, purple and black on Solar Fire are basic process colors. The gray, green, red and blue are Pantone colors mixed from process colors. With some practice it's fairly easy to discern process colors. Mixed colors are another story.
Things we have learned along the way
Screen printing is like golf. Looks fairly easy, maybe is harder than it looks to get just right.
Solar Fire was a terrible playfield to start on. The art is somewhat complex, the playfield edges and inserts vary between boards and the factory screen printing had lots of errors. Trying to sort that out with a computer has been a challenge.
Instead of asking for all the playfields at once, we should have collected a couple to use for the creation of files, screens and color selections then accepted them all for work when we had everything sorted out. Thanks to your patience it is working this way, but we could have reduced customer turnaround by doing it differently. Next time we will have a better plan.
Just because you get a collection of computer files that looks good on a monitor doesn't mean it will translate well in the real world. We have created dozens of images the screens could not handle and/or did not fit the playfield as intended. Back to the drawing board, many times.
Color processing and ink behaviors between 1981 and 2023 is not an easy translation. What I wouldn't give for oil-based paints. Water based paints may be environmentally friendly and have come a long way, but they still suck.
Hand screen printing is a dying art. Most the products available today are designed for small hobby projects or for clothing and paper-based goods, much of that printed by computer-controlled monster print machines. We have made most of our tools, which means we are doing it with the same technology they used in about 1950. It works but we are inventing the wheel all over again.
I suppose some of this sounds pessimistic, but I don't mean for that to be the case. Things are actually going well and we are learning a lot. I do want to thank all of you that have playfields with us, and I appreciate your interest and patience along the way. Should be some good results soon.
Tim Crowley
Las Vegas Playfields