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Originally Posted by darwinchristian |  | | | | | | | | | i realize my line of questioning is vague. i apologize. i guess i'm just looking for any tips before i spend the next month vigorously testing everything. | |  | |  | |
Your problem is that the smallest dots are burning away. The "easy" answer it to drop the LPI of the halftone. Drop own to a 35 LPI and all of the dots will be big enough not to get lost.
It is possible to modify the artwork not to need calibrating with a transfer function, by adjusting the output levels in the levels dialog box.
There is a downside to using the levels command, rather than a transfer function. By using a levels command, something you want to be printed BLACK would be output using a 90% screen. By using the transfer function, BLACK would be printed at 100%, which would cause an intentional over saturation of ink. While a transfer can give 110%, at 90% it would yield 90%.
The issue with using levels is that it will take as much testing to determine the correct value as you would using a transfer function.
If you have photoshop, it should only take a day. Your already very close.
The only thing which might take you a month is to find a good tutorial on how to use a transfer function in a program other than photoshop. I just attempted to find a tutorial on the subject and couldn't come up with anything.
fred