Thanks for the reply macdevin. Full disclosure-I've posted this issue in the past and Gordo has been a wealth of information, but we still see the tonal jump in some gradients. We do high end applique work and the clients are extremely critical. We output film to a Megasetter, resolution is at 2540, line screen is usually between 50 and 80lpi depending on content and angles range from 7 to 52 degrees. We use custom mixed inks-NO process colors and lots of metallics which dictate the mesh we use depending on the amount and size of the metallic flake they contain. We have tried multiple dot shapes and angles. It is not banding in the traditional sense, the gradients on film are completely smooth. It is the interaction of the mesh, film, ink and press. As Gordo explained, there is chaining of the dot that occurs at different points in the gradient depending on the shape of the dot used and it is at that point where we get a bump in density causing an unsightly line. Without revealing any trade secrets I was hoping someone could point me in the right direction.
