Troubleshooting Print Defects on Rigid Media: What to Look For and How to Fix It

Whether you’re printing on foam boards, display boards, acrylic, corrugated plastic, or wood panels, knowing how to identify and fix common issues will help you deliver flawless results, job after job.

Here’s a quick guide to diagnosing and correcting defects when printing directly to rigid digitally printable substrates.

1. Banding or Striping in Solid Colors

What it looks like: Visible horizontal or vertical lines across the print, especially in solid areas or gradients.

Possible causes:

• Misaligned or clogged printheads

• Incorrect media height or vacuum setting

• Inconsistent ink pressure or feed rate

• Static buildup on substrate surface

Fix it by:

• Running nozzle checks and performing printhead cleaning

• Rechecking media gap settings and alignment

• Increasing vacuum suction for better media hold-down

• Using an anti-static brush before printing

2. Ink Pooling, Smearing, or Over-Saturation

What it looks like: Ink doesn’t dry fully, puddles on the surface, or smears when handled.

Possible causes:

• Substrate is non-porous or incompatible

• Incorrect ink profile or excessive ink limits

• Curing lamp settings are too low or out of sync

Fix it by:

• Verifying the substrate is coated or optimized for UV/latex inks

• Reducing ink density or changing to the correct ICC profile

• Increasing lamp power or dwell time in the curing process

3. Poor Adhesion or Ink Flaking

What it looks like: Ink scratches off easily or flakes when bent or cut.

Possible causes:

• Surface energy of the substrate is too low

• Material wasn’t cleaned or prepped properly

• Incorrect ink chemistry for the surface type

• Material was printed on the wrong side (common with coated boards)

Fix it by:

• Using substrates with higher surface energy or primer

• Wiping surfaces with IPA before printing

• Switching to adhesion-promoting inks or primers

• Double-checking print side and surface treatment

4. Dust, Lint, or Surface Blemishes

What it looks like: Tiny particles, bumps, or smudges embedded under the ink layer.

Possible causes:

• Dusty environment or unclean substrate

• Static electricity attracting airborne particles

• Mishandling of boards pre-print

Fix it by:

• Cleaning each board before printing (with IPA or lint-free cloth)

• Installing air purifiers or static eliminators near the press

• Handling boards with gloves or edge grips to avoid oil transfer

5. Warping or Buckling During Print

What it looks like: Board doesn’t stay flat on the bed, leading to head strikes or uneven prints.

Possible causes:

• Material exposed to humidity or temperature changes

• Vacuum bed settings too weak

• Substrate thickness beyond machine spec

Fix it by:

• Conditioning rigid boards in the print room before use

• Increasing vacuum hold-down or using mechanical clamps

• Verifying media thickness tolerances for your printer

Pro Tip: Know Your Media Specs

Many rigid substrates require:

• Specific ink types (UV-curable vs. hybrid vs. latex)

• Coatings or primers for printability

• Anti-static and surface energy treatments

Always consult the technical data sheet or use a substrate search platform like Substrate Bank to confirm compatibility before running a job.

Conclusion: Quality Starts with Diagnosis

Rigid media offers standout results — but only if your process is dialed in. By understanding the most common print defects and how to solve them, you’ll minimize waste, reduce reprints, and maintain the kind of quality that earns long-term client trust.

Because in high-impact digital print, the surface might be flat — but your standards shouldn’t be.