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221. Printing and embossing

A method of rapid prototyping and manufacture of surface coverings having a substrate, a print layer and a wear layer, the method comprising: a. producing aprototype surface covering using a digital printing system to print the print layer and a press to emboss the wear layer, wherein the press comprises an embossing tool selected from the group consisting of an embossing plate and an embossing roll, theembossing tool made by three-dimensional printing, and b. using the digital printing system and press to fill the commercial product pipeline.

Developing new designs for surface coverings, by producing a prototype to show a potential customer prior to making a mass produced product available, is expensive and typically takes three months or more. This is mainly due to the cost and timeto develop print cylinders and embossing cylinders.

Customers are demanding shorter and shorter development times and more input into the final design of the product. It would be advantageous to have a means to quickly (within a matter of days) modify a design, produce a prototype that willfaithfully imitate the final product, and be capable of producing commercial quantities of the final product at a rate to meet initial commercial demand.