Vinyl is one of the most commonly used materials in graphics, signage, and surface applications in industries in the United States. Vinyl is versatile, cost-effective and highly visual, whether it comes to advertising and promotion, or architectural signage and vehicle graphics. Modern printing technologies have led to the possibility of printing almost any graphic on a vinyl substrate, which is a key material in American made decals.
Two major types of vinyl are used in making decals: calendared and cast vinyl. Both are made of similar raw materials; however, their manufacturing process, performance, cost, and the best application is very different. These differences are critical in choosing the appropriate vinyl and attaining the required durability and looks.
This paper describes the manufacturing process of calendered and cast vinyl, their performance under actual real-life conditions, and the areas of their application. Knowing these differences, designers, printers, and buyers can make the correct choices and prevent the avoidance of unnecessary expenditures or early breakdown.
Vinyl Production.
Vinyl is a resin that is in the form of small pellets of polyvinyl chloride. PVC is inherently hard and hence extra components are added in the manufacturing process to enable the material to be flexible, colored, and perform. These additives are plasticizers, pigments, UV absorbers, heat stabilizers, fillers and processing aids. The combination and quality of these ingredients is significant in the end performance of the vinyl film.
Calendered and cast vinyl separate at the manufacturing process.
Calendared Vinyl Manufacturing.
Calendared vinyl is made by heating the vinyl resin to a thick, sticky mass which is pressed between a series of large, smooth rollers. These rollers press and heat the material to thin and uniform sheets. The vinyl is made thicker, thinner and flatter as it goes through several roller gaps until the final thickness and surface finish have been achieved.
This process can be used to produce high volumes of production and uniform thickness. Calendared vinyl is usually smooth and either matte or gloss and is produced in gauges that are usually between 1.5 to 3 mil.
Cast Vinyl Manufacturing
Cast vinyl is produced through casting. Organosol is poured on a paper or polyester casting sheet. The vinyl is then dried in ovens where the solvents are evaporated and they are left as a solid film. The casting surface determines the texture and finish of the vinyl.
Cast vinyl is very stable in terms of dimensions because it is not stretched in a mechanical manner and is thus formed in a relaxed state. Cast films are about 2 mil in thickness and then covered with adhesive. Such an approach is more flexible, durable, and conformable.
Calendared Vinyl
Economy or standard vinyl is also known as calendared vinyl. It is also popular because it is cheap and flexible.
The main Properties of Calendared Vinyl.
Manufacturing Process
- Squeezed between hot rollers.
- Automated, fast production.
- Thickness and smoothness are consistent.
Typical Uses
- Short-term outdoor signage
- Indoor wall graphics
- Flat decals and lettering
- Advertising illustrations and point of purchase.
The benefits of Calendared Vinyl.
- Cost effective and economical.
- Big range of colors and glosses.
- Easy to cut and handle
- Appropriate to flat and slightly curved surfaces.
Drawbacks of Calendared Vinyl.
- Reduced life span as compared to cast vinyl.
- Tend to become smaller and crack.
- Limited conformability
- Reduced resistance to extreme weather.
Calendared vinyl is available in different formulations depending on the durability. Economy grades can be used one year outside and high-performance polymeric calendered films can be used up to seven years under controlled conditions.
Cast Vinyl
Cast vinyl is regarded as the best in decal production. Its production and choice of raw materials lead to excellent performance.
The most important features of Cast Vinyl.
Manufacturing Process
- Vinyl is cast onto a sheet.
- Baked without mechanical tension.
- Flexible, thin, and dimensionally stable.
Common Applications
- Fleet graphics and vehicle wraps.
- Outdoor billboards and outdoor signs.
- Graphics on marine and recreational vehicles.
- Perforated window films
Advantages of Cast Vinyl
- Very good durability and life span.
- Better adherence to complicated curves.
- Minimal shrinkage over time
- Increased UV/weather resistance.
- Paint-like finish
Applications of cast vinyl are usually applied where long life performance is paramount. A lot of the cast films have five to twelve years outdoor warranty.
The Major Dissimilarities between Calendared and Cast Vinyl.
Durability
Cast vinyl is much more resistant than calendered vinyl. It has a relaxed manufacturing process leading to the reduction of internal stress and hence shrinkage and cracking. Calendared vinyl, on the other hand, does not dissipate the pressure of roller compression and will shrink in the presence of heat.
Thickness and Stability
The thickness of cast vinyl films is usually 2 mil and their size remains constant with time. Calendared vinyl may be between 1.5 and 3 mil but it has higher dimensional movement.
Applications
Calendared vinyl is ideal in flat applications that are short term. Cast vinyl is good in the long-term outdoor applications, and intricate surfaces like rivets, corrugations and compound curves.
Cost
Cast vinyl typically has a price that is two to three times higher than calendared vinyl. Its extended life cycle however makes it more economical in the long run.
Performance and Durability
Weather Resistance
Cast vinyl is more resistant to UV radiation, extreme temperatures, moisture and abrasion. Most cast films contain UV inhibitors and protective top layers that ensure fading and cracking are prevented.
Calendared vinyl is not as protective and tends to break easily when it is exposed to long-term sunlight and heat.
Shrinkage
Shrinkage is also a vital performance parameter in decal. Calendared vinyl can contract as much as 1/32 inch in a 24 inch distance in a year. Cast vinyl usually contracts by half or less, hence it is suitable in precise graphics and automotive applications.
Industrial Applications.
Outdoor Signage
Long-term outdoor signage is best done using cast vinyl because it is durable. Calendared vinyl can be used in temporary outdoor banners or seasonal displays.
Vehicle Graphics
Car wraps must be very flexible and durable. Cast vinyl enables graphics to be stretched out without lifting body panels. Calendared vinyl can only be applied to flat surfaces of vehicles and temporary decals.
Indoor Signage
Calendered vinyl is a cost-efficient solution to indoor applications that have flat surfaces. Cast vinyl is suggested when more durability or surface complexity is required.
The Right Vinyl to Your Needs.
In choosing vinyl to use in American made decals, one should take into consideration the following:
- Project duration and budget
- Surface complexity
- Environmental exposure
- Printing and cutting specifications.
- Removability expectations
- Regulatory or certification requirements.
Selecting the proper vinyl guarantees the maximum performance and prevents the needless replacement expenses.
Conclusion
The cast and calendared vinyl are differentiated in terms of manufacturing, durability, and suitability of use. Calendared vinyl is cost effective and suitable for short term, flat use. Cast vinyl offers a better performance in terms of long-term outdoor performance and complex surfaces.
Knowledge of these differences can enable designers and purchasers to choose the appropriate material to the appropriate job. The right choice of the vinyl guarantees improved outcomes, extended durability, and higher worth in the American made decals.
