The Production Process
Engraving
Production of United States paper currency is not an easy or simple task, but one that involves over 65 separate and distinct steps in the production process. Money begins with the hand-engraved piece of soft steel, known as a master-die. Separate portions of the design, such as the portrait, the vignette, the ornamentation, and the lettering are hand-cut by the engravers. If you look closely at a currency note, you will notice that the portrait consists of numerous fine lines, dots and dashes which vary in size and shape. The magnificent artistry and skill of the engraver bring the portrait to life. The process of engraving is the first step in a unique printing technique known as intaglio printing.
Siderography
In simplest terms, siderography is the means by which multiple images of the hand-engraved die are transferred to a printing plate.
Plate Making
The master die is subjected to tremendous pressure, heated and an impression of the die is taken. An alto and/or relief (a raised image of the die) is cast in plastic. Multiple plastic images of the various components (such as the decorative scrollwork) of the note are made, fitted and welded into the necessary plate configuration consisting of thirty-two notes. Plastic altos are placed in an electrolytic tank and are used to produce a series of plates, which are then cleaned, polished, and carefully inspected by an engraver. If the plates pass the scrutiny of the engraver, the final chromium coated basso (recessed image) plate is made and another multiple subject intaglio plate is ready to place on the printing press.
Printing
We print currency on medium-speed, sheet-fed rotary presses, which are capable of printing over 300 sheets per hour. Each sheet is forced, under extremely heavy pressure (estimated at 20 tons), into the finely recessed lines of the plate to pick up the ink. The printing impression is three dimensional in effect and requires the combined handiwork of highly skilled artists, bank note engravers, and plate printers. The surface of the note feels slightly raised, while the reverse side feels slightly indented. The backs of the notes are printed with green ink, allowed to dry for 24 to 48 hours. The faces are then printed with black ink and also allowed to dry.
Overprinting
We then overprint your selected picture using modern laser printers and a special ink designed to last for decades.
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