SunDance is proud to announce the addition of digital iFoil and Jetvarnish capability, sometimes called inline digital hot foil in the Konica Minolta and MGI platform, digital foil stamping, or (poorly) sleeking.

The MGI process is more closely aligned with high-end digital embellishment platforms like Scodix. Both MGI and Scodix deliver industrial-level digital embellishment including spot UV, raised effects, and digital hot foiling without using traditional dies or screens. Each system uses advanced registration technologies, supports a wide range of substrates, and enables short-run, premium, and personalized/variable data embellishment. The latest generation of MGI technology offers superior reliability, production speed, and overall print quality. It strengthens our capabilities for short-run packaging, rapid prototypes, and multi-version work across nutraceuticals, cosmetics, specialty foods, and premium consumer brands.

How it Works

The iFoil process applies real foil using digitally-controlled heat and pressure over a fresh UV varnish layer, matching the quality of traditional die-based foiling. We are most excited that it makes shorter runs of foiled products cost-effective, and enables foiling personalized or variable designs rather than needing to stick with a custom die. It creates a crisp, clean transfer with outstanding definition.

SunDance selected this system for its performance, stability, and advanced registration capabilities. The machine uses a high-precision scanner that reads each sheet and aligns the artwork to correct for stretch, skew, drift, or cutting variance. It delivers extremely consistent results across production because it maintains a tight registration tolerance that supports fine detail and complex multi-pass embellishment.

We are still working to fully integrate iFoil into our production. We will create standardized designer guidelines, streamline file submission and prepress, and automate some job ID and naming conventions.

What it Can Do

The technology supports an extensive variety of foil colors and finishes, including metallic, holographic, pigment, gloss, and specialty options. There are many things it can do that cannot be accomplished with traditional foil stamping, including

• Micro textures
• Fine line detail
• Variable patterns
• Multi-pass foil layers
• Raised varnish textures
• Foil on foil
• Sculpted varnish layers
• Greyscale-driven dimensional pattens
• Precise combinations of foil with spot UV

Where to Use It

This capability expands embellishment options for folding cartons, packaging, wide-format boards, labels, marketing collateral, direct mail, and premium commercial print. There are endless combinations of digital foil, raised spot UV, textures, and our in-house laminating and finishing. Custom effects like these elevate retail presence, improve unboxing experiences, and differentiate your brand.

What We’ve Learned

The SunDance technical team was trained on machine operation, foil behavior, varnish thickness management, scanner modes, substrate performance, multi-pass sequencing, job costing, preventive maintenance, and workflow integration. We tested foils across coated paper, laminated sheets, soft touch surfaces, layered stock, and some synthetic substrates. We evaluated varnish thickness levels based on substrate type, including the higher thickness requirements for HP Indigo prints due to the risk of surface matte shifts under heat. And we reviewed best practices for foil placement, stretch behavior, stamp area configuration, and workflows that reduce foil waste.

SunDance’s mission is to deliver innovative manufacturing solutions that enhance brand expression and provide measurable value. Adding iFoil and Jetvarnish gives our customers more powerful ways to create memorable, luxurious print and packaging experiences. Contact us today to see how our capabilities can make your project stand out!