Printing system and method including printing roll having elastically deformable and compressible thick inner layer

A printing system comprising:

• a printing roll comprising an elastically deformable and compressible inner layer and a thin outer shell to cover the inner layer, wherein the thin outer shell includes a pattern of raised print features to receive ink material thereon, the inner layer is softer and thicker than the thin outer shell, and the thin outer shell and the inner layer have a thickness ratio not greater than about 0.5;
• an impression roll positioned adjacent to the printing roll, and a nip formed between the printing roll and the impression roll;
• and
• a flexible web being advanced along a machine direction through the nip;
• wherein the thin outer shell has a thickness in a range from about 1.52 mm (0.030 inch) to about 6.35 mm (0.250 inch).

A method of printing a pattern of features onto a web, the method comprising:

• providing a printing roll comprising:
• an elastically deformable and compressible inner layer and a thin outer shell to cover the inner layer, wherein the thin outer shell includes a pattern of raised print features to receive ink material thereon, the inner layer is softer and thicker than the thin outer shell;
• supplying a liquid ink onto the pattern of raised print features of the printing roll;
• and applying an impression force to press the printing roll and the web against each other to transfer the liquid ink from the printing roll to the web to form the pattern of features;
• wherein the printing roll is pressed with an impression in a range from about 0.0254 to 0.508 mm (1 to 20 mils) with respect to a printing “zero” impression.