I need the impossible

I am trying to create some graphics on the Edge FX and am faced with the demand for a large field of solid color. While this is not my first rodeo, I have only rarely seen any Edge printer do large fields of color without a few minor flaws or little specs of missing color. in some cases, on the right colors, I can sometimes touch up the print with a sharpie, but this print is the most challenging one I've had to do.

Here are some more specs:
>Substrate: Lexedge II
>Color1: Dark Grey
>Color2: White (set as backing)
>Includes just a couple clear bits
>Scale: 26"x11"
>File has a few small areas of text and graphics, but is primarily solid Dark Grey with a white backing.

If anyone has solved a problem like this, I'd love to know how. I have tried pens from the art store, a handful of different printer settings, voodoo, and so far I'm getting one perfect print out of five.

Thanks for reading

CSI label department lead

 

hmm...

I really curious about that antistatic gun. We may just have one lying around for all I know. Unfortunately, I am using 3m adhesive on the back of a reversed image (so as to view the image through the lexan). Also, some parts require a clear window, so vinyl is not going to work. I am going to try more tweaks to drop the temperature on the dark grey.

Please, anyone else with advice or reccomendations, continue posting.

Thanks, guys, for your suggestions.

 

Improved, but still not there.

It's really the dark grey I'm having the trouble with. I have far less trouble with the white these days as I've installed a filtered fan blowing over the foil as it enters.. It's reduced the dust by a LOT. I also clean the print head, brushes and squeegees. the problem is that I still get bit missing in the dark grey. If the grey were more opaque, I'd love to double it, but so far, that just means the holes (the quantity of which doubles with a second layer) are a noticeably lighter. Sometimes, under some settings there is a "halo" effect where the middle gets coverage, but the edges of the spot don't get any foil at all.

I have used mask under my 3m adhesive to create non adhesive areas, but not on this project. We really need the color to match, and since the dark grey is so transparent, We really need one clean layer of dark grey and one clean layer of white. Frankly, the color is transparent enough that if the label has any bubbles under it, you can see a color difference. Since these go on finished product, They need to be solid.

Keep the solutions coming everyone. We're improving over here, but not there yet.