In a flexographic printing workshop, if you’re unsure which

cell shape to choose, a 60-degree hexagonal pattern is almost always

a safe bet. As the most prevalent and efficient cell structure in the

industry, it accounts for over 90% of the flexographic market. Why

has it become the “go-to” solution? Today, we’ll take a deep dive

into the 60-degree cell, examining its characteristics through the

lenses of geometric structure and ink-transfer mechanics.

Geometric Advantages: Maximizing Space Utilization

The core strength of the 60-degree hexagonal pattern lies in its

exceptional space utilization. For any given surface area, it features

the thinnest cell walls (the partitions between cells) and the largest

opening area. This means that at the same screen count (line count),

it can hold more ink than shapes like the quadrangular pyramid,

resulting in a greater and more uniform ink transfer.

Furthermore, the arrangement of regular hexagons effectively

prevents or mitigates the occurrence of moiré patterns (interference

fringes) during high-speed printing, ensuring high-quality output.

Ink-Transfer Performance: Eliminating “Dead Zones”

Because there are fewer intersections between cell walls, the

60-degree pattern reduces wear on the doctor blade and significantly

minimizes “dead zones” where ink might otherwise get trapped. The

ratio of the opening width to the depth is optimally designed

(approximately 0.28), ensuring smooth ink release. This prevents

issues where ink at the bottom of a cell—if the cell were too deep or

narrow—might fail to transfer or become difficult to clean out.

Versatility: Perfectly Suited for Everything from Cartons to

Labels

Solid areas/coarse lines (low screen count, <300 LPI):

Leverages its high-volume capacity to provide an ample supply

of ink.

Fine dots/text (high screen count, >750 LPI): Can be adapted

into an elongated hexagonal variant, maintaining fine detail andink-carrying capacity without increasing cell depth. (It is

recommended that the anilox screen count be 4–5 times the

screen count of the printing plate; this prevents small highlight

dots from sinking into the cells, which would otherwise lead to

excessive dot gain.)

Maintenance Notes: Prevent Impacts and Clean Regularly

The cell walls of the hexagonal honeycomb structure are

extremely thin and have limited physical strength. Take great care to

avoid impacts during handling; any scratches from hard objects will

permanently impair the ink-carrying capacity of the affected area.

More importantly, timely daily cleaning is essential. Dried ink

can easily become trapped within the fine honeycomb cells, causing

clogs. Regular deep cleaning using an ultrasonic cleaner is

recommended to ensure optimal ink release.

Q:What materials are 60-degree cells suitable for?

A:They are highly versatile and suitable for a wide range of

applications, including standard cardboard boxes, flexible packaging,

and labels.

Q:How can I tell if the cells are worn?

A:Check for a decrease in print density, or use a magnifying glass to

see if the cell walls have been worn flat.

Q:What is the typical BCM (ink-carrying capacity)?A:The range is quite broad—from 2.0 BCM for fine-dot printing to

over 15 BCM for solid-area printing—and should be customized

based on specific printing requirements.