Patent Publication Number: US-7717035-B1

Title: Embossing apparatus and method for mounting embossing plates

Description:
FIELD OF THE INVENTION 
   The present invention relates generally to an apparatus and method for embossing a substrate. More particularly, the present application involves an embossing apparatus and method that include a pair of embossing plates for creating a clean and sharp embossing in line as a one pass process. 
   BACKGROUND 
   Embossing involves the creation of a three-dimensional image in a substrate such as paper, foil, laminate or other ductile material. The process involves passing the substrate through a nip formed by a die and a counter die. The die is sometimes referred to as a female die and has a desired pattern formed therein. The counter die, often called a male die, has a matching pattern that is received into the pattern of the die. The substrate is passed between the die and counter die and through a combination of heat and pressure has the desired pattern formed thereon. The pattern is formed at a level above that of the surrounding substrate. Although finding utility in a variety of applications, embossing is commonly applied to seals, postage stamps, and labels for food, beverages, cosmetics, cigars and wine. 
   One type of device currently used to form an embossing is a rotary device that includes a pair of hard embossing rolls that are cylindrical in shape. The rolls are typically made of steel or brass and have the desired pattern etched thereon. Although this type of device is capable of forming an embossing on a substrate, the cost for such a device is high and it generally takes a long amount of time to machine these types of rolls. Further, the cost to ship such a set of cylindrical rolls is high due to their weight and size. 
   An additional method of embossing currently used is photopolymer embossing. This process makes use of a pair of photopolymer embossing plates, that have a desired image imparted thereon, that are mounted to a pair of adjacent cylinders by double sided mounting tape. After application, one of the cylinders acts as a die and the other acts as a counter die. The substrate can be fed through the nip formed by the pair of photopolymer embossing plates to have an embossing formed thereon. Although this type of process works well for its intended purpose, embossing formed by photopolymer embossing plates generally has a low profile and poor edges. Also, this embossing technique is limited to forming only a two dimensional embossing and cannot form a three dimensional embossing. Further, adhesive on the double sided tape used to apply the photopolymer embossing plates to the cylinders is susceptible to breaking down and causing the photopolymer embossing plates to detach. 
   Another current process used to form an embossing employs a photopolymer metal backed embossing plate. This plate is a male die and is attached to a magnetic cylinder to be held thereon. A female die is not used. Instead, a rubber roller forms a nip with the photopolymer metal backed embossing plate and pushes the substrate down on top of this plate to form a two dimensional embossing thereon. Although this type of method is capable of forming an embossing, the resulting product generally has a very low profile in addition to poor height and edges. 
   It is also possible to create an embossing through the use of flat plates. These plates are generally made of brass, copper or magnesium. Male and female patterns are etched into the plates, and the substrate is positioned between the plates in order to be embossed. Embossing tools of this type are costly and are not suited for various types of manufacturing processes. As such, there remains room for variation and improvement within the art. 
   SUMMARY 
   Various features and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned from practice of the invention. 
   One aspect of the present invention provides for an apparatus for embossing a substrate that includes a die with a metal backing layer that carries a polymer layer. The polymer layer has a female pattern formed thereon through the use of laser engraving. The metal backing layer is capable of being magnetically attached to a magnetic cylinder. A counter die is also included and has a metal backing layer that carries a polymer layer. The polymer layer of the counter die has a male pattern formed thereon through the use of laser engraving. The metal backing layer of the counter die is capable of being magnetically attached to a magnetic cylinder. 
   Another aspect of the present invention is found in an apparatus as immediately mentioned in which the polymer layer of the die is a carbon rubber compound. Further, the polymer layer of the counter die is a carbon rubber compound. 
   A further aspect of the present invention is found in an apparatus as discussed above that further includes a female magnetic cylinder. The female magnetic cylinder has at least one row of neodymium magnets for attracting the metal backing layer of the die to magnetically attach the die to the female magnetic cylinder. A male magnetic cylinder is also present and has at least one row of neodymium magnets. The magnets are used for attracting the metal backing layer of the counter die to magnetically attach the counter die to the male magnetic cylinder. 
   An additional aspect of the present invention resides in an apparatus as previously mentioned in which the polymer layer of the die has a female starting member formed thereon. The polymer layer of the counter die has a male starting member formed thereon. The male starting member is receivable into the female starting member in order to engage the die and counter die at a proper starting point. Proper engagement allows the female pattern of the die to be properly received with the male pattern of the counter die during rotation of the die and counter die. 
   A further aspect of the present invention is provided in an apparatus as discussed above in which the polymer layer of the die has a female register tract formed thereon. The polymer layer of the counter die has a male register tract formed thereon. The male register tract is receivable into the female register tract in order to maintain the die and counter die in register with one another during rotation of the die and counter die. 
   Another aspect of the present invention exists in an apparatus for embossing a substrate that has a die. The die has a polymer layer that has a female pattern thereon. The die is capable of being attached to a cylinder. The polymer layer of the die has a female starting member thereon. A counter die that has a polymer layer with a male pattern thereon is also present. The counter die is capable of being attached to a cylinder. The polymer layer of the counter die has a male starting member thereon. The male starting member is receivable into the female starting member in order to engage the die and counter die at a proper starting point so that the female pattern of the die is properly received with the male pattern of the counter die during rotation of the die and counter die. 
   Also provided in accordance with one aspect of the present invention is an apparatus as immediately described in which the polymer layer of the die has a second female starting member thereon. The polymer layer of the counter die has a second male starting member thereon. The second male starting member is receivable into the second female starting member in order to engage the die and counter die at a proper starting point so that the female pattern of the die is properly received with the male pattern of the counter die during rotation of the die and counter die. 
   The present invention also provides for in an additional aspect an apparatus for embossing a substrate that has a die. The die has a polymer layer that has a female pattern thereon. The die is capable of being attached to a cylinder. The polymer layer of the die has a female register tract thereon. A counter die is present and has a polymer layer that has a male pattern thereon. The counter die is capable of being attached to a cylinder. The polymer layer of the counter die has a male register tract thereon. The male register tract is receivable into the female register tract in order to maintain the die and counter die in register with one another during rotation of the die and counter die. 
   Also provided in accordance with another aspect of the present invention is an apparatus as immediately mentioned in which the male and female register tracts have an elongated rectangular shaped component with spokes extending perpendicular to the direction of elongation. The male register tract is located outside of the pattern of the polymer layer of the counter die. The female register tract is located outside of the pattern of the polymer layer of the die. 
   An additional aspect of the present invention is provided in an apparatus as discussed above in which the polymer layer of the counter die has a second male register tract thereon. The polymer layer of the die has a second female register tract thereon. The second male register tract is receivable into the second female register tract in order to maintain the die and counter die in register with one another during rotation of the die and counter die. 
   Another aspect of the present invention exists in a method of mounting a die and a counter die for use in embossing. The method includes the steps of providing a die with a metal backing layer that carries a polymer layer. The polymer layer has a female pattern thereon. A counter die with a metal backing layer that carries a polymer layer is also provided. The polymer layer has a male pattern thereon. The method also includes the steps of providing a female magnetic cylinder and a male magnetic cylinder. The metal backing layer of the die is magnetically attached to the female magnetic cylinder. The metal backing layer of the counter die is magnetically attached to the male magnetic cylinder. The polymer layers of the die and counter die form a nip. 
   Another aspect of the present invention resides in a method as immediately discussed that further involves engaging a male starting member on the polymer layer of the counter die to a female starting member on the polymer layer of the die. A male register tract is engaged on the polymer layer of the counter die to a female register tract on the polymer layer of the die. 
   A further aspect of the present invention exists in a method as described above in which a leading edge of the die is taped to a leading edge of the counter die. The counter die is engaged onto a register location of the male magnetic cylinder. The female magnetic cylinder and male magnetic cylinder are rotated so that the leading edges of the die and counter die are passed through a nip formed by the male magnetic cylinder and female magnetic cylinder. The tape is removed from the leading edges of the die and counter die. The female magnetic cylinder and male magnetic cylinder are rotated so that the step of magnetically attaching the metal backing layer of the die to the female magnetic cylinder and the step of magnetically attaching the metal backing layer of the counter die to the male magnetic cylinder is accomplished. 
   These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended Figs. in which: 
       FIG. 1  is a front view of a die with a female pattern in accordance with one exemplary embodiment of the present invention. 
       FIG. 2  is a side view of the die of  FIG. 1 . 
       FIG. 3  is a front view of a counter die with a male pattern in accordance with one exemplary embodiment of the present invention. 
       FIG. 4  is a side view of the counter die of  FIG. 3 . 
       FIG. 5  is a perspective view of the die and counter dies of  FIGS. 1-4  with their starting members and register tracts engaged. 
       FIG. 6  is a side view of male and female cylinders with engaged die and counter dies with the leading edge of the counter die aligned with a register location of the male cylinder. 
       FIG. 7  is a side view of the male and female cylinders advanced from their position in  FIG. 6 . 
       FIG. 8  is a side view of the male and female cylinders advanced from their position in  FIG. 7  in which taped leading edges of the die and counter die are moved through a nip formed by the male and female cylinders. 
       FIG. 9  is a side view of the male and female cylinders advanced from their position in  FIG. 8  with the die and counter die completely attached. 
   

   Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention. 
   DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS 
   Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a third embodiment. It is intended that the present invention include these and other modifications and variations. 
   It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170-190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5. 
   The present invention provides for an apparatus  10  capable of creating an embossing  44  in a substrate  12 . The apparatus  10  includes a die  14  and a complimentary counter die  22  between which the substrate  12  passes in order to have the embossing  44  imparted thereon. A female starting member  46  and a male starting member  48  can be included in order to properly position the die  14  and counter die  22  when mounted onto cylinders  34  and  38 . Further, a female register tract  54  and a male register tract  56  can be incorporated into the die  14  and counter die  22  in order to cause these two components to register properly when rotating in unison on the cylinders  34  and  38 . In accordance with various exemplary embodiments of the present invention, the die  14  and counter die  22  can be magnetically attached to a female magnetic cylinder  34  and a male magnetic cylinder  38 . Further embodiments exist in which a female pattern  20  formed on the die  14  and a male pattern  28  formed on the counter die  22  are thus formed through the use of laser engraving. 
   An apparatus  10  in accordance with one exemplary embodiment of the present invention includes a die  14  as shown in  FIGS. 1 and 2 . Die  14  may include a metal backing layer  16  that carries a polymer layer  18 . The polymer layer  18  may be rubber in accordance with one exemplary embodiment. In accordance with yet another exemplary embodiment polymer layer  18  may be a carbon rubber compound. The polymer layer  18  can be attached to the metal backing layer  16  in a variety of manners. For example, the polymer layer  18  can be bonded to the metal backing layer  16  with adhesive  30  under heat or alternatively in a cold mounting bonding process in accordance with various embodiments. The polymer layer  18  has a female pattern  20  of a shape desired to be imparted onto a substrate  12  in an embossing process. The female pattern  20  can be formed into the polymer layer  18  or may be carried thereon in accordance with various exemplary embodiments. In one embodiment, the female pattern  20  is formed into the polymer layer  18  through the use of laser engraving. 
     FIGS. 3 and 4  show a counter die  22  of an apparatus  10  in accordance with one exemplary embodiment of the present invention. Counter die  22  may have a metal backing layer  24  that carries a polymer layer  26 . As described above with respect to die  14 , polymer layer  26  may be rubber and may be attached to the metal backing layer  24  in a variety of manners such as through the use of an adhesive  32 . Also, polymer layer  26  may be a carbon rubber compound in certain exemplary embodiments. The polymer layer  26  has a male pattern  28  formed thereon. As previously discussed, the male pattern  28  can be integral to the polymer layer  26  or may be a separate component that is attached thereto. The male pattern  28  is formed through the use of laser engraving in accordance with one exemplary embodiment. Male pattern  28  is complimentary of female pattern  20  and is used in order to provide a desired embossing  44  into substrate  12 . 
   Die  14  and counter die  22  can include a number of features to aid in their mounting. For example, die  14  can be provided with a female starting member  46  located outside of the female pattern  20 . A second female starting member  50  and a third female starting member  78  are also included. As shown, the female starting member  46  is circular in shape, second female starting member  50  is square in shape, and third female starting member  78  is rectangular in shape. It is to be understood, however, that other exemplary embodiments of the present invention are possible in which the aforesaid members are provided with different shapes. Also, although shown as being outside of the female pattern  20 , any one of or all of the female starting members  46 ,  50  and/or  78  can be located in pattern  20  in accordance with other embodiments. 
   Polymer layer  26  of counter die  22  includes three male starting members  48 ,  52  and  80 . Male starting member  48  is circular in shape, second male starting member  52  is square in shape, and third male starting member  80  is rectangular in shape and all of the starting members  48 ,  52  and  80  are located outside of male pattern  28 . As with the female starting members  46 ,  50  and  78 , the male starting members  48 ,  52  and  80  may be variously shaped and may be located in male pattern  28  in accordance with other exemplary embodiments. The starting members are configured to engage one another so that female starting member  46  engages male starting member  48 , second female starting member  50  engages second male starting member  52 , and third female starting member  78  engages third male starting member  80 . The engaging starting members are complimentary to one another and their engagement is shown in  FIG. 5 . The starting members function to allow the die  14  and counter die  22  to engage one another at a proper starting point so that the female pattern  20  is properly received with the male pattern  28  when the die  14  and counter die  22  are engaged and rotated. Although described as having three starting members on each of the die  14  and counter die  22 , other embodiments exist in which fewer or more starting members can be employed. For example only the female starting member  46  and male starting member  48  may be present in accordance with one exemplary embodiment. 
   Referring back to  FIG. 1 , die  14  is shown as having a female register tract  54  that extends from a leading edge  86  to a tailing edge  88 . In other embodiments, the female register tract  54  may only extend a portion of the way between edges  86  and  88 . Female register tract  54  is located outside of the female pattern  20  but may be located in female pattern  20  in other embodiments. Female register tract  54  includes an elongated rectangular shaped component  62  that has a plurality of spokes  64  that are evenly spaced from one another and are oriented perpendicular to the elongated rectangular shaped component  62 . These features are located between a pair of elongated grooves  82  of the female register tract  54  that are parallel to one another. The elongated rectangular shaped component  62 , spokes  64  and elongated grooves  82  may all be of the same depth or may have varying depths in accordance with other embodiments. 
   The female register tract  54  is designed to receive a male register tract  56  located on the polymer layer  26  of the counter die  22 . The male register tract  56  extends from a leading edge  90  of the counter die  22  to a trailing edge  92 . It is to be understood, however, that the male register tract  56  need not extend the entire length of polymer layer  26  in other embodiments but may instead extend a distance less than the distance from leading edge  90  to trailing edge  92 . The male register tract  56  includes features similar to the female register tract  54 . For example, the male register tract  56  has an elongated rectangular shaped component  66  that extends from leading edge  90  to trailing edge  92 . A series of spokes  68  extend from the elongated rectangular shaped component  66  and are oriented perpendicular therewith. The spokes  68  are generally evenly spaced from one another in the direction from leading edge  90  to trailing edge  92 . A pair of elongated rectangular shaped edges  84  is located on either side of the spokes  92  and elongated rectangular shaped component  66 . The features  66 ,  68  and  84  of the male register tract  48  are received in respective features  62 ,  64  and  82  of the female register tract  46 . The female and male register tracts  54  and  56  engage one another in order to maintain the die  14  and counter die  22  in register with one another during their rotation. This helps maintain correct alignment of the die  14  with counter die  22  so that female pattern  20  is properly aligned with male pattern  28  to create a desired embossing  44 . 
   Again, it is to be understood that the configuration of the tracts  54  and  56  is only exemplary and that other variations are possible. For example, tracts  54  and  56  may be a series of evenly or unevenly spaced projections and depressions that are not continuous with one another and extend half way across the length of the edges  86  and  88  and across half way of the length of edges  90  and  92  in certain embodiments. 
   A second female register tract  58  can be included on polymer layer  18  and located so that the female pattern  20  is located between tracts  54  and  58 . Although shown as having a second female register tract  58 , the die  14  need only include a single tract  54  in certain embodiments. Alternatively, more than two register tracts can be included in other variations of the present invention. Additionally, it is to be understood that the shape of the various tracts can be different in other embodiments and that the disclosed shapes are only exemplary. The second female register tract  58  is shown to extend completely between the leading edge  86  and trailing edge  88  of die  14 . Other variations are possible in which the second female register tract  58  extends only part way between the opposed edges  86  and  88 . The second female register tract  58  includes features such as an elongated rectangular shaped component  70 , spokes  72  and a pair of elongated grooves  94 . Features  70 ,  72  and  94  can be provided, arranged or varied in the same manners discussed above with respect to the elongated rectangular shaped component  62 , spokes  64  and the pair of elongated grooves  82  of the female register tract  54 . 
   The second female register tract  58  receives a complimentary second male register tract  60  located on the polymer layer  26  of counter die  22 . The register tracts  58  and  60  are receivable in order to maintain the die  14  and counter die  22  in register with one another during rotation. The second male register tract  60  extends completely between the leading edge  90  and trailing edge  92  of the counter die  22 . Other variations are possible in which the second male register tract  60  extends less than the full distance between edges  90  and  92 . The second male register tract  60  includes features such as an elongated rectangular shaped component  74 , spokes  76  and a pair of elongated rectangular shaped edges  96 . Features  74 ,  76  and  96  can be arranged in a similar manner, configuration or with variations similar to the elongated rectangular shaped component  66 , spokes  68  and pair of elongated rectangular shaped edges  84  of the male register tract  56  as previously discussed. 
   The die  14  and counter die  22  can be mounted onto a pair of cylinders  34  and  38  by first engaging the female starting member  46  and male starting member  48  in addition to the second female starting member  50  and the second male starting member  52 . This engagement helps ensure the die  14  and counter die  22  are aligned and started properly. Additionally, the female register tract  54  and male register tract  56 , as with the second female register tract  58  and second male register tract  60 , will likewise be engaged. Next, as shown in  FIG. 6 , a piece of tape  100  can be applied to the leading edges  86  and  90  of the die  14  and counter die  22  to attach these two components to one another at this location. Also as shown in  FIG. 6 , the die  14  and counter die  22  can be moved into position next to a female magnetic cylinder  34  and a male magnetic cylinder  38 . The cylinders  34  and  38  can be configured in a variety of different manners in order to be magnetic. In one exemplary embodiment, at least one row of neodymium magnets  34  can be arranged around the circumference of the female magnetic cylinder  34  in order to cause cylinder  34  to be magnetic. In a similar manner, at least one row of neodymium magnets  40  are arranged around the male magnetic cylinder  38  to likewise impart magnetism thereto. 
   In accordance with one exemplary embodiment of mounting the die  14  and counter die  22 , the taped leading edges  86  and  90  can be moved into the position shown in  FIG. 6  in which the leading edge  90  of counter die  22  is engaged onto a register location  104  located on the male magnetic cylinder  38 . Register location  104  can be a register scribe or register pin on the male magnetic cylinder  38  in accordance with various exemplary embodiments. 
   The female magnetic cylinder  34  and male magnetic cylinder  38  can be rotated so that the leading portion of metal backing layer  16  of die  14  magnetically engages female magnetic cylinder  34  and so that the leading portion of metal backing layer  24  of counter die  22  magnetically engages male magnetic cylinder  38 . This advancement and engagement is shown in  FIG. 7  in which the leading edges  86  and  90  are located in a nip  102  formed by the female magnetic cylinder  34  and male magnetic cylinder  38 . 
   The female magnetic cylinder  34  and male magnetic cylinder  38  can be continued to be rotated until the taped leading edges  86  and  90  are moved out of nip  102  and are positioned a slight distance therefrom. For example, the taped leading edges  86  and  90  may be moved a distance of one inch from nip  102  in accordance with one exemplary embodiment. At this point, a user may stop rotation of the female magnetic cylinder  34  and male magnetic cylinder  38  and remove tape  100 . Doing so allows the metal backing layers  16  and  24  to magnetically attach to the male and female magnetic cylinders  38  and  34  as they are rotated. Complete engagement of metal backing layers  16  and  24  is shown in  FIG. 9  in which the die  14  and counter die  22  are shown to be completely mounted onto the male and female magnetic cylinders  38  and  34 . Interlocking of the female register tract  54  and male register tract  56 , in addition to the second female register tract  58  and second male register tract  60 , helps keep the die  14  and counter die  22  in register with one another during their rotation. If desired, lock down pressure can be applied between the female magnetic cylinder  34  and male magnetic cylinder  38  in order to create a nip  98  between the embossing plates of a desired pressure. 
     FIG. 9  also shows an idle roller  42  positioned proximate the female magnetic cylinder  34  and male magnetic cylinder  38 . A substrate  12  such as paper, foil or other material may be passed over the idle roller  42  and directed first onto the polymer layer  18  of die  14 . Doing so may be advantageous in stopping or limiting creasing, registration and tension problems that may occur during embossing of the substrate  12 . However, it is to be understood that in other embodiments the substrate  12  may first contact the polymer layer  26  of counter die  22  or may simultaneously contact polymer layers  18  and  26 . Further, it is to be understood that the presence of idle roller  42  is not necessary in other embodiments. The substrate  12  can if desired be heated before being passed through a nip  98  formed by polymer layers  18  and  26  of die  14  and counter die  22 . Doing so may help prevent tearing of the substrate  12  when embossing high profile shapes. Passing of substrate  12  through nip  98  causes the male pattern  28  on counter die  22  to press the substrate  12  into the female pattern  20  on die  14 . This application of pressure causes an embossing  44  to be formed on the substrate  12 . 
   A variety of manufacturing processes may be used to construct the different components of the apparatus  10 . The metal backing layers  16  and  24  can be thin sheets that may be up to 0.008 inches in thickness in accordance with one embodiment. The polymer layers  18  and  26  can be vulcanized, bonded or otherwise applied to the metal backing layers  16  and  24  in strips that are 24 inches wide by 30 feet long. The combined layers  16  and  18 , along with combined layers  24  and  26 , may be ground to various thicknesses such as 0.029 inches, 0.034 inches, 0.039 inches, 0.045 inches and/or 0.065 inches. It is to be understood, however, that the combined layers  16  and  18 , in addition to combined layers  24  and  26 , may be from 0.010 inches to 0.25 inches in thickness in accordance with certain exemplary embodiments. The thickness of the counter die  22  is generally subject to the substrate  12  that is being embossed. The outside diameter of the die  14  is usually made to match the true pitch diameter of the female magnetic cylinder  34  to which the die  14  is mounted. The combined layers  16 ,  18  and  24 ,  26  can then be cut to sheets of 24 inches by 36 inches in size. 
   The combined layers  16 ,  18  and  24 ,  26  can then be attached to a magnetic cylinder in a rotary laser engraver. The laser engraver may then ablate into polymer layers  18  and  26  patterns  20  and  28  having desired shapes, depths and distortions. The laser engraver may also ablate the starting members  46 ,  48 ,  50 ,  52 ,  78  and  80  into the polymer layers  18  and  26 . Still further, the female register tract  54 , male register tract  56 , second female register tract  58  and second male register tract  60  can also be ablated into polymer layers  18  and  26 . The starting members and register tracts can be ablated into the waste area of the polymer layers  18  and  26  so that their image is not imparted onto the substrate  12  during the embossing process. 
   The male pattern  28  can be formed with a 2.5 pixel soft shoulder/edge in accordance with one exemplary embodiment of the present invention in order to reduce possible tearing of the substrate  12  on embossed edges. The female pattern  20  can be provided with hard edges. After or during laser engraving, the die  14  and counter die  22  can be pre-bent or rolled. Pre-bending or rolling is shown in  FIG. 5 . A 100 step 8 bit TIF file may be used to calibrate the laser engraver to image a full tonal range from highlights to shadows. Each step may be adjusted to 1/100 addition of total relief. The depth of example step  25  will be adjusted to be ¼ the overall relief depth, and step  50  will be adjusted to be ½ of the overall relief depth and so forth. Software is employed in order to convert 8 bit TIF and vector art into a series of micro lines having varying thicknesses, angles and spacing on the same die  14  or counter die  22  to generate a holographic illusion. Typically, the laser engraver employed utilises a modulated laser. A single laser may be used if a dual laser system is employed in which the second laser is dormant. The die  14  and counter die  22  can be washed with water once laser engraving is completed. Although described as employing lasers to manufacture various features of the die  14  and counter die  22 , it is to be understood that other machines and processes may be used to construct the aforementioned elements or features of the apparatus  10 . 
   The female and male magnetic cylinders  34  and  38  may be ground under true pitch diameter otherwise known as undercuts or bare cylinder diameter. The undercuts or bare cylinder diameter is provided in order to match product repeat lengths and die  14  and counter die  22  thickness. The die  14  and counter die  22  can be manufactured to fit magnetic cylinders  24  and  38  with an undercut of 0.019 inches, 0.029 inches and/or 0.045 inches. The counter die  22  is usually between 0.001 inches to 0.029 inches thicker than the die  14  and stands higher than the true pitch diameter of the male magnetic cylinder  38 . Utilisation of 0.019 inch undercut male magnetic cylinders  38  and 0.029 inch undercut female magnetic cylinders  34  with 0.029 inch dies  14  reduces the laser image time by half. This is because both die  14  and counter die  22  can be imaged simultaneously because the focus of the laser engraver is identical. This situation is contrasted to that in which a 0.029 inch die and a 0.039 inch counter die are employed that requires different optical focus from one another. 
   The apparatus  10  may be arranged so that a counter die  22  of 0.029 inches and 0.034 inches on a 0.019 inch undercut male magnetic cylinder  38  is present. Alternatively, a 0.69 inch counter die  22  may be used on a 0.045 inch undercut male magnetic cylinder  38 . The die  14  can be made to match the undercut or bare cylinder diameter to which the die  14  is mounted such as 0.029 inches and 0.045 inches. The female magnetic cylinder  34  and male magnetic cylinder  38  are manufactured to match the product&#39;s repeat length and width with the required undercut or bare cylinder diameter best suited for the thickness of the substrate  12  to which the embossing  44  is applied. The disclosed process can be used in current presses, converting equipment and finishing equipment with an existing die station. Further, the current process may be used in a stand alone station and/or in embossing modules. The present process may make use of a customer&#39;s current printing and/or converting equipment and allows for embossing in line as a one pass process. The current process allows for 2D embossing  44  to be produced in which the embossed image has a single height. Additionally, 3D embossing can be accomplished in accordance with the present invention in which the embossed image has multiple levels, heights and contours. 
   While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.