When it comes to sign making and printing, choosing the right vinyl is crucial for a successful outcome. The options can be overwhelming, but understanding the differences between monomeric, polymeric, and cast vinyl will help you make an informed decision. In this article, we'll explore the pros and cons of each type of vinyl and provide guidance on their recommended uses.
Monomeric Vinyls
Monomeric vinyls are commonly used for interior applications and selective short-term external applications. These vinyls contain plasticisers with short-chain chemical bonds, which means they don't bind as efficiently into the film. Over time, the plasticisers can migrate from the film, leaving it brittle. Monomeric films are usually stiff and less conformable over contours, making them suitable for flat-sided applications only.
Recommended uses for monomeric films: Interior work and short-term external applications where a lifespan of 1-3 years is expected. Also a great option for promotional work such as stickers due to the thickness and cost effectiveness.
Pros
- Ideal for flat-sided applications
- Lower in price compared to other vinyl types
- Stiffer/thicker films for easier handling
Cons
- Not suitable for uneven or contoured surfaces
- Susceptible to shrinkage and cracking over time
Shop our range of Monomeric Vinyls here.
Polymeric Vinyls
Polymeric vinyls offer improved performance compared to monomeric vinyls. These vinyls contain long-chain plasticisers that bind more efficiently into the film, reducing migratory effects such as cracking. They are less prone to shrinkage and have a longer outdoor life expectancy. While they are suitable for most external applications, their conformability over complex contours is somewhat limited.
Recommended uses for polymeric films: Interior and external applications where cast films are not a suitable option. Ideal for flat or slightly curved surfaces.
Pros
- Longer lifespan compared to monomeric vinyls
- Less shrinkage than monomeric films
- Ideal for flat and slightly curved applications
- Stiffer/thicker films for easier handling
- Expected lifespan of 3 to 7 years
Cons
- More expensive than monomeric calendared vinyls
- Not highly conformable
Shop our range of Polymeric Vinyls here.
Cast Vinyls
Cast vinyls are the top choice when dimensionally stable applications are required. These vinyls are manufactured using a casting process, where liquified resin is coated onto casting film. The result is an extremely thin film of vinyl with minimal shrinkage. Cast vinyls are soft, flexible, and easy to cut, weed, and apply. They offer exceptional conformability over complex contours, making them ideal for extreme exterior applications like vehicle wraps.
Recommended uses for cast films: Suitable for most types of work where durability and conformability are essential. Ideal for interior and external applications, including vehicle wraps.
Pros
- The longest lifespan for vinyls
- Superior durability and dimensional stability
- No shrinkage
- Soft, flexible, and thin, allowing for excellent conformability
- Better UV performance compared to other vinyl films
- Expected lifespan of up to 10 years
Cons
- Price is higher than monomeric and polymeric vinyls
Shop our range of Cast Vinyls here.
Calendared vs. Cast Vinyls: Manufacturing Process and Differences
Vinyls are manufactured using either the calendaring or casting process, which impacts their characteristics and performance. Calendared vinyls are extruded or rolled, resulting in less dimensional stability compared to cast films. Calendared films are generally cheaper but are more prone to shrinkage. On the other hand, cast vinyls are manufactured in a less stressful process, where a liquid resin is poured over a liner resulting in better dimensional stability and performance.
Calendared Vinyls
Calendared vinyls are either monomeric or polymeric, depending on the structure of the plasticisers used. Monomeric calendared vinyls have smaller molecule sizes, leading to more molecular migration and potential effects on adhesives and laminates. These vinyls may become brittle over time and experience shrinkage. Polymeric calendared vinyls, on the other hand, have longer molecular chains and larger molecules, reducing migration and improving longevity, flexibility, and film stability.
Cast Vinyls
Cast vinyls are manufactured by pouring resin onto a casting film, resulting in an extremely thin and highly conformable film. They offer superior dimensional stability, colour pigmentation, UV stability, and gloss levels. Cast vinyls do not retain "memory" like calendared vinyls, resulting in minimal shrinkage. They are ideal for complex contours, such as rivets and corrugations, and perform exceptionally well in extreme exterior applications and vehicle wraps.
Overview
Choosing the right sign vinyl is crucial for the success of your projects. By understanding the differences between monomeric, polymeric, and cast vinyls, you can make an informed decision based on your specific requirements. Monomeric vinyls are suitable for short-term applications, while polymeric vinyls offer improved longevity. Cast vinyls provide the highest level of durability and conformability, making them ideal for demanding applications.
Remember to consider the surface you'll be applying the vinyl to, the expected lifespan of the project, and your budget when making your decision. If you have any further questions or need assistance in choosing the right vinyl for your projects, don't hesitate to reach out to us. Our experts are here to help you achieve the best results with our range of self-adhesive vinyls.
