Systems and methods for handling a flexible web

A web handling system, comprising:

• a plurality of cross-grooved idler rollers comprising a first set of idler rollers and a second set of idler rollers;
• an imaging drum;
• a nip roller adjacent the imaging drum and forming a nip therewith;
• at least one printhead adjacent the imaging drum and movable with respect to the imaging drum;
• a spreader roller disposed between the first set of idler rollers and the nip roller;
• wherein the second set of idler rollers is disposed at a downstream location from the imaging drum;
• wherein each idler roller is disposed no more than 36 inches from an adjacent idler roller, spreader roller, and nip roller;
• wherein the spreader roller is disposed no more than 9 inches from the nip;
• at least one sensor adapted to detect web thickness;
• and
• a control system responsive to the at least one sensor and adapted to move the at least one printhead.

A web handling method, comprising the steps of:

• providing a web system comprising a plurality of cross-grooved idler rollers, an imaging drum, a nip roller adjacent the imaging drum and forming a nip therewith, and a spreader roller disposed between the plurality of cross-grooved idler rollers and the nip roller, disposing each idler roller, spreader roller, and nip roller no more than a first distance from an adjacent idler roller, spreader roller, or nip roller wherein the first distance is in a range of 38 to 28 inches, 36 to 30 inches, or 35 to 33 inches;
• disposing the spreader roller no more than a second distance from the nip the second distance is in a range of 6 to 11 inches, 6.5 to 9 inches, or 7.0 to 8.5 inches;
• and
• transporting a flexible web through the web system.