How to UV Print on Baseballs: Best Practices and Common Challenges

Editor's Note: This article was written for Promo Impressions. For more content on promotional products decoration, be sure to subscribe to the biweekly newsletter at PromoImpressions.com. 

Custom printing baseballs is not an unusual request for King Print & Design Co. We specialize in uniquely printed items — from personalization to awards and keepsakes. While printing on baseballs may seem challenging, the process is simple with the proper tools and equipment.

Equipment and Technologies for Printing Baseballs

We use two Mimaki UV flatbed printers — the UJF-6042MkII and the Mimaki UJF-7151 Plus II (super gap) — for printing on a wide variety of round or non-flat objects. For baseballs, we primarily use the UJF-6042MkII with flexible inks, as it provides the precision and adaptability needed for curved surfaces.

Credit: King Print & Co.

One key feature that makes this printer ideal is its long-distance printing technology, allowing us to print on contoured or uneven surfaces, such as sports balls and even rocks. Using long-distance printing Level 2, we can achieve a 1.5" diameter print area on baseballs while maintaining excellent clarity and crisp lines. For larger objects with a greater diameter, the print area increases accordingly.

The Process of Printing on Baseballs

When first venturing into printing sports balls, we developed a target test design to determine the largest possible logo or graphic that could be printed clearly. This target consisted of concentric rings spaced ⅛" apart, expanding outward to 2" or larger, depending on the item. By using this test print, we could identify the point at which lines or text became too blurry, helping us refine our process for each unique item.

Top view of the target printed on the baseball.

Credit: King Print & Co.

The larger target printed on the baseball.

Credit: King Print & Co.

The smaller target printed on the baseball.

Credit: King Print & Co.

The target set at a 2.5" print test range.

Credit: King Print & Co.

Prepping the Baseball

Since baseballs are made of leather or synthetic materials, proper surface preparation is crucial. Any oils or residues on the surface can affect ink adhesion. Begin by cleaning the baseball thoroughly to ensure a smooth and consistent print. We use a lint-free rag to remove any heavy contaminants and then a lint roller to remove any small particles left behind.

Ink Layering for Absorbent Surfaces

Leather is an absorbent substrate, which presents a unique challenge. To combat ink bleeding, we apply two layers of clear ink as a base. This creates a stable surface for the color inks to adhere to. We opt for clear ink instead of white for two key reasons:

1. Minimal Visibility: If any bleeding occurs, it’s less noticeable than with white ink.
2. Gloss Finish: Clear ink allows us to create a smooth, glossy print area, reducing the impact of the leather’s texture on the final design.

Once the clear ink base is applied, we print logos or graphics using CMYK inks only. The natural white color of the baseball serves as a built-in background, eliminating the need for an additional white layer.

Softball Printing Adjustments

Softballs typically come in a bright yellow color, which poses a different challenge. Unlike baseballs, we lay down a white ink base layer before applying color to softballs. This ensures that colors appear accurate and vibrant while providing a solid foundation for any white elements in the design.

Challenges in Baseball Printing

Printing on a curved and textured surface, like a baseball, comes with some obstacles.

1. Registration & Alignment: Since baseballs have seams and natural inconsistencies, precise alignment is essential. We use a custom jig to hold each baseball securely in place, ensuring consistent placement for every print.

The jig ensures the baseballs don't shift during printing. | Credit: King Print & Co.

2. Ink Adhesion & Bleeding: As mentioned, leather and synthetic materials absorb ink differently. The double-layer clear ink base prevents bleeding and enhances adhesion, leading to a sharper final print.

3. Maintaining Consistency in Large Orders: For bulk printing jobs, consistency is key. We calibrate our printer settings and use identical jigs to maintain uniformity across multiple baseballs. Additionally, regular test prints ensure that colors and details remain consistent throughout the batch.

Experimentation & Lessons Learned

Over time, we’ve experimented with different techniques to refine our printing process. Here are some key takeaways:

What Works

• Using rotating jigs minimizes distortion and maintains alignment.
• Printing multiple ink layers enhances color vibrancy.
• Adjusting print height and speed ensures sharp, detailed graphics.

What Doesn’t Work

• Printing too close to the seams can cause ink buildup and inconsistencies.
• Coated or glossy baseballs require primers to ensure proper ink adhesion.

Advice for Other Promotional Product Printers

If you're considering expanding into unique applications like printed baseballs:

1. Invest in the Right Fixtures: A well-designed jig makes a significant difference in achieving precise and repeatable prints.
2. Test Before Production: Run sample prints with different ink settings to determine what works best for each substrate.
3. Understand Your Printer’s Capabilities: Adjusting ink flow, curing times, and print height is crucial for curved surfaces.
4. Market Your Unique Service: Custom-printed baseballs are excellent for promotions, sports teams, and memorabilia, making them a valuable niche product.

By mastering these techniques, we’ve created high-quality, custom-printed baseballs that stand out in the promotional printing industry. With the right equipment, preparation, and experimentation, other printers and promotional products suppliers can expand into this unique and profitable market.