Apparatus and method for adding a registered image on a sheeted substrate

A system for preparing sheeted substrate with a registered cast image comprising:

• a) a master web supplying mechanism;
• b) a master web with registration marks with a distance between registration marks on the master web being equal or less than a fixed distance between sheets;
• c) a resin coated sheeted substrate in a form of a series of spaced sheets with leading or trailing edges acting as reference positions;
• d) an independently driven first nip roller set acting as a pulling roller set that defines a first nip point for the master web downstream from an unwind of the master web roll that travels at a slower or equal line speed relative to a line speed of a final nip point;
• e) an independently driven second nip roller set acting as a stable roller set that creates a second nip point for the master web downstream from the first nip point and that travels at a same line speed as the line speed of a final nip point;
• f) a pressure roller that nips the master web and the resin coated sheeted substrate against a power driven impression cylinder;
• g) a powered conveying mechanism located prior to the impression cylinder to carry the resin coated sheeted substrate to the final nip point;
• h) a device for curing a coated resin on the resin coated sheeted substrate;
• i) a first sensor to detect registration marks on the master web;
• j) a second sensor for detecting reference positions of the resin coated sheeted substrate;
• and
• k) a computing system to calculate a timing of each registration mark to the final nip point at which the master web is nipped to the resin coated sheeted substrates and varying a relative speed between the master web and the resin coated sheeted substrate to synchronize respective registration marks as the respective registration marks reach the final nip point.