Signages dominate your sights day and night. From attractive signs on glass walls to being on 3D shapes, effective signage advertisements or informative messages can never go unnoticed. If you plan to start your own business or regularly print signages, learning the fundamentals of materials used and weighing their pros and cons is crucial. 

This comprehensive guide delves into the world of digital signage products, empowering you to make informed decisions for your next project. We’ll explore various factors to consider, delve into the properties of popular materials, and provide specific guidance on selecting the perfect film type – cast, polymeric calendared, or monomeric calendared – for your needs, with insights from leading vinyl sign suppliers.

What Is A Vinyl Film?

Vinyl was invented in 1920, and today, it is the second-largest manufactured and sold plastic resin. Also known as polyvinyl chloride, or PVC, vinyl is a thermoplastic material that can be reprocessed using heat. Vinyl film is made from PVC and has various applications due to its durability, versatility, and ease of application. Typical uses of vinyl film include signage, decals, vehicle wraps, and decorative elements. Vinyl films are popular in commercial and personal projects for their ability to transform surfaces quickly and affordably while providing long-lasting results.

Types Of Vinyl Film

There are two broad categories of vinyl film: cast and calendared vinyl, which differ in their manufacturing and applications. 

Cast films

Unlike other vinyl films, cast vinyl boasts a unique production process. This type of film goes through casting, where a liquid mixture of PVC and other ingredients is poured onto a moving platform and then heated to remove solvents. This results in a thin, stretchy, and highly modifiable film. Cast vinyl films are usually around 2 millimeters thick.

Calendared vinyl

Calendering offers a faster and more cost-effective way to produce vinyl film. Solid PVC material is continuously fed through heated rollers, applying pressure and heat to flatten and shape it into the desired film thickness. While this method creates a thicker and less expensive film, it also reduces stretch and has less scope to change shape than cast vinyl. Calendered vinyl films are typically 2.5 to 4 millimeters thick.

One key factor differentiating cast vinyl from calendered vinyl is the type of plasticizer used.  Plasticizers are essential additives that enhance the flexibility and workability of PVC. However, there are two main categories with distinct characteristics:

Polymeric Plasticizers: These high-grade plasticizers offer superior performance. They form strong bonds with the PVC molecules, resulting in a more durable and flexible film that resists cracking and maintains its properties over time. This is why cast vinyl, which utilizes polymeric plasticizers, boasts exceptional durability and conformability.

Monomeric Plasticizers: These economy-grade plasticizers offer a lower-cost option. However, they have weaker bonds with the PVC, leading to potential plasticizer migration of the film over time. This can cause the film to become brittle and shorten its lifespan. Due to their use of monomeric plasticizers, monomeric calendered vinyl films are best suited for short-term indoor or shaded outdoor applications where flexibility and long-term durability are not essential. 

Applications Of Different Vinyl Films

Cast vinyl

• Large outdoor banners because of strong resistance to harsh sun, rain
• Storefront displays for sharp detailing of logo, letters, and colors
• Small and large vehicles like trucks with complex curves
• Ships and boat graphics, decals, high-performance floor graphics

Monomeric Calendered Vinyl:

• Promotional displays, sale signs, and point-of-purchase materials
• Window graphics that require frequent change
• Temporary murals on flat surfaces

Polymeric calendered vinyl:

• Outdoor signs (as it can resist some direct sunlight)
• Indoor Signage like murals, window graphics, POP displays
• Vehicle graphics with few curves

Factors to Consider When Choosing the Type of Vinyl

Durability: Depending on your usage and the application of the film, you may choose cast vinyl for its durability. If you’re flexible, you will get more stability with polymeric calendared film. Monomeric calendar film is best for short-term indoor or shaded applications.

Flexibility: Cast vinyl is the best choice if you need your sign to be placed around some curves or corners or placed on uneven surfaces. Go for a polymeric film calendar if the surface can take up some balance. Being thicker, monomeric calendared is best for flat surfaces.

Budget: When looking for a longer-lasting, sturdy performance, it’s advisable to spend money on cast vinyl film for your signage. Monomeric calendared is the most budget-friendly option, but you may have to compromise on its limited lifespan and flexibility. 

Takeaway

Choosing the right digital signage products can feel overwhelming, with many options available. You can narrow down your choices by considering the application, desired lifespan, and budget. Revisit your goals to understand the vinyl film types and the strengths and limitations of the cast, polymeric film calendar, and monomeric calendar film that will work well for your application and budget.  

Remember, the ideal material becomes a part of your promotional tools in your signage project, amplifying your message and ensuring it reaches your target audience. By selecting the perfect match, you’ll create signage that’s not only visually captivating but also endures the elements and delivers long-lasting value. Use your creativity confidently when choosing the signage material that best suits your needs.