Order fusing foil
Metallic on 1" cores
Metallic on 1/2" cores.
Pigment, holographic & security foils
are available under the supplies tab.
What is foil fusing?
Foil fusing is a process where foil is bonded to a toner image area that
was created using either a laser printer or a copy machine.
What types of foils are available for foil
Gold, sliver, metallic colors, pigment colors, and special application
foils like glitters, as well as, decorative and security holographic
Is a die required to produce foil fusing?
No. Foil fusing does not require any type of die. Laser printer and/or
copy machine toner is used to bond the foil to the paper.
Can a foil fuser be used to produce blind or foil
A foil fuser can only apply flat foil and be used to "ThermoFuse" sheets
with a toner image area. While a blind emboss effect can not be created,
a foil embossed effect can be created with certain papers using a
process called "ThermoEmbossing".
Are all laser printer and copy machine toners
compatible for foil fusing?
No. Certain laser printers and copy machines, and certain toners are not
suitable for foil fusing. If you have any questions about the
suitability of your printer and/or toner, we will be happy to run
compatibility tests on your samples.
Does fusing foil only stick to black toner?
No. Foil will fuse to all toner image areas regardless of color.
Are any special skills required to produce high
quality foil fusing?
No. There is no "makeready" or other special skills required to produce
foil fusing. When using compatible papers, printers/toners and foils,
operators are only required to set the appropriate speed and temperature
for the type of foil and paper being run.
How much does it cost to foil fuse an 8 1/2" by
11" area with gold foil?
Foil costs vary but customers usually figure about $.04 per 8 1/2" by
11" sheet for gold or silver metallic foil. Keep in mind that metallic
colors, pigment and special application foils are typically more
expensive than gold and silver.
Do I need a foil cutter?
Yes and no. Customers can purchase foil pre-cut to specific widths but
this is often inconvenient and wasteful if you wind up being forced to
run a job with a roll that is wider than necessary. Purchasing foil in
24"-25" wide rolls, then cutting the specific width required for each
job will minimize foil waste and cost.
Do you have to run a foil width that matches the
No. Foil fusing only requires that the foil width be slightly wider than
the toner image area to be foil fused. Using foil cut slightly wider
than the image area, plus the ability to run sheets portrait or
landscape helps to minimize foil waste and expense.
What is the maximum paper thickness that can be
The limiting factor in maximum paper thickness while foil fusing is
based on the maximum sheet thickness you can run on your laser
Can the foil draw be controlled to match the
length of the image area to minimize foil waste?
No. There is no foil draw control on a foil fuser. When paper is being
fed through the machine and the impression is engaged, foil is drawn at
the linear rate of the paper. Foil waste can be minimized using the
proper foil roll width and by how the sheet is run through the fuser.
Can rewound foil or fusing film be reused?
No. Foil and fusing film that has been through the fusing mechanism and
rewound is waste.
Can I foil fuse on both sides of a sheet in one
pass through the Foil-Tech?
Yes. Latest generation automatic and manual Foil-Tech models can apply
up to two rolls of foil to the top of the sheet and one color of foil to
the bottom of the sheet in one pass. Foil-Tech models are sold with a
single foil unwind/rewind. Additional unwind/rewind stations are
What is "ThermoFusing"?
ThermoFusing is a process where a sheet that has been imprinted with
toner is run through a foil fuser with clear fusing film instead of
foil. As the sheet passes through the fuser, the toner is aggressively
remelted under pressure from the fusing rollers with the smooth fusing
film surface in contact with the toner. ThermoFusing enhances the toner
image area in three ways. It improves the durability of the image on the
sheet, it smoothes out the toner density across the image area, and it
changes the surface finish of the toner image to a gloss finish.
Can I "ThermoFuse" and foil fuse at the same
Yes. Foil fusing requires a higher temperature than ThermoFusing.
However, by using fusing film with a release agent coating, foil fusing
and ThermoFusing can be run at the same time.
Can Foil-Tech equipment be used for any process
besides foil fusing and ThermoFusing?
Yes. Manual and Automatic Foil-Tech machines can also be used to run
single or two sided thermal laminating jobs.
What happens when toner is applied over offset
The foil will only adhere to the toner image area and will not transfer
to the offset ink.
Can I lay down two or more colors of foil within
the same image area if the foil areas don't overlap?
Yes. Imprint toner and foil fuse the first color, then apply the second
toner image area and foil fuse the second color. All foils have
different "laser proof" characteristics, customers need to understand
these and their laser printer/copy machine characteristics (see
Important Notice on Foil-Tech page of this web site).
Can I produce tight registration, multicolor foil
images by running the sheet through the laser printer/copy machine and
fuser multiple times?
No. Laser printers and copy machines can not accurately register
multiple images imprinted in multiple passes.
Can I fuse "foil on foil" by running the sheet
through the laser printer/copy machine and
Yes and no. Foil can sometimes be fused on foil. However, the top layer
of foil often doesn't bond aggressively to the bottom layer of foil. As
a result, the top layer of foil may not adhere uniformly or may be
scrapped off the lower layer if it is exposed to rough handling. Due to
unpredictable results, we do not recommend this process.
Can I foil fuse stocks that are not perfectly
smooth, like laid?
Some lightly textured papers can be foil fused. However, foil fusing
will not crush the texture flat like traditional foil stamping. As a
result, the paper surface texture will show through the fused foil. Foil
fusing results on even lightly textured stocks can be unpredictable.
Do different papers affect the foil finish when
Yes. Compatible very smooth or coated stocks will provide more of a
mirror finish when fusing bright finish gold, silver and metallic
colors. Compatible uncoated stocks will foil fuse well but with less of
a mirror finish. Keep in mind, paper type and finish also affect the
foil finish that can be achieved using traditional foil stamping.
How does paper thickness affect foil fusing?
Foil fusing is a heat process. As a result, thicker papers will require
a higher fusing temperature and more dwell (slower out put speed) than
How can I maximize foil fusing speed?
Foil fusing productivity is based on a linear fusing rate for a given
type and thickness of paper. Running sheets landscape, whenever possible
will maximize through put.
What is the smallest type that can be used with
We recommend 6 pt type as a minimum size that can be foil fused without
letter plugging. Results may vary depending on the type of
printer/toner, foil and paper used, and the fusing speed and
Can I combine large solid areas at the same time
I am fusing small type?
Yes. One of the interesting characteristics of foil fusing is that you
can fuse large solids at the same time you are fusing small, fine line
Can sheets be run through an offset press after
they have been foil fused?
Yes. Offset printing and/or printing with a digital duplicator will not
affect the foil image area.
Can sheets be thermographed after they have been
Yes. During all our testing, foil fused sheets can be thermographed
without damaging the finish on the fused foil.
Can foil image areas be embossed on a second
machine after being foil fused?
No. Laser printers and copy machines do not apply the toner image area
accurately enough on the sheet to allow the foil fused image to be
Can you foil fuse pre-printed greeting cards and
other products that have embossed or foil embossed image areas on the
Pre-converted social stationery and greeting cards that are to be run on
a foil fuser must be design for this process. First, these products must
be able to run through a laser printer or copy machine to create the
toner image. Embossed areas must not be too deep, too sharp edged or too
close to the toner image area. Personalization of pre-converted social
stationery and greeting cards has proven to be the largest foil fusing
application to date. The fusing mechanism does not seem to flatten or
harm the embossed image areas.
Can you run envelopes through the foil fuser?
Standard (lick and stick style) envelopes are usually not "laser printer
compatible" and may seal as they pass through the heated fusing rollers.
Laser printer compatible (peal and seal style) envelopes foil fused well
during our tests.
Can you run pressure sensitive (crack and peel)
stock through the fuser?
Many pressure sensitive paper stocks are suitable for foil fusing.
Plastic and synthetic pressure sensitive materials may not be suitable.
Can foil fusing be used for security
Yes. There are three transparent and three silver holographic security
foils currently available. These foils have micro text patterns. Some
customers also use standard holographic pattern foils as a security
How can I find suitable papers for foil fusing?
THERM-O-TYPE provides a list of papers that have been successfully
tested for foil fusing on our web site. This list is an excellent
resource for customers. In general, papers with a smooth surface finish
What are transparent holographic pattern foils
and how are they used?
Transparent holographic pattern foils are used to apply a holographic
pattern effect over single, spot or full color text and graphics. These
foils can be used to create a wide range of visual effects.
What is "ThermoEmbossing"?
ThermoEmbossing is a process that allows a foil embossed effect
to be created while foil fusing. By applying varying amounts of toner
within the image area, the image appears embossed after foil fusing.
While this effect can be dramatic, it can only be used on certain
Can I use white fusing foils on dark colored
Yes. White pigment foil can be fused on dark stocks, including black.
White is currently a very popular fusing foil color.
Can "scratch off" foil products be produced with
Yes. Using the "Freedom Foil" process and special "scratch off"
laminating film, scratch off products can be produced with foil fusing.
Can text and/or graphics be foil fused over
complex toner backgrounds?
Yes. Using the "Freedom Foil" process and gloss or matte "PermaFoil"
laminating films, foil text and/or graphics can be fused over toner
background images. This process is used for book covers, tickets, etc..
Can foil fusing be applied to any clear plastic
Yes. Clear acetate can be run through many laser printers and then foil
fused. Please check to ensure your laser printer is suitable before
running plastic materials.