Choosing the Right Vinyl

As a manufacturing company, one of the most frustrating setbacks occurs when the materials you purchase fail to perform as desired. In our industry, we have hear this story told countless ways: 

"I ordered my decals in bulk, but after sitting on the shelf, they would not perform properly. I ended up discarding thousands of dollars' worth of supplies."

This is a common frustration that often is attributed to ordering decals made out of a material not equipped for the task. In selecting vinyl, there are two primary options: calendered and cast. Understanding how each type is produced, their differences, and their intended applications is essential to ensuring the correct vinyl is selected for the job. 

CALENDERED:

Calendered vinyl is rolled out from a putty-like state into a thin sheet similar to process of making pasta. It requires less production space and can be manufactured more efficiently in large quantities. Compared to cast, it is the thicker option ranging between 3-6 mil. As it ages and is exposed to weathering conditions, calendered vinyl tends to shrink back to its original form causing peeling around the edges. Manufacturers have developed variations by adding anti-shrinking agents in this vinyl to reduce retraction, offering a more efficient variety of high-quality calendered vinyl. Typically it yields a life expectancy of 3-5 years.

Calendered vinyl is much more affordable and a practical solution for indoor applications, flat projects with little stretch, or projects requiring a shorter service.

CAST:

Cast is poured into molds when hot and cooled into ultra-thin sheets, 1.5-3 mil. This production requires additional room for molds and increases time between production for cooling. These conditions result in higher production costs. Being formed in a flat mold, yields a product that maintains its flat shape throughout its life and is less likely to shrink, lift or pull away from the application surface. Cast vinyl is expected to last between 7-10 years, nearly doubling the lifespan of calendared products.

Cast vinyl, while more expensive than calendered, is recommended for outdoor applications with surfaces frequently exposed to heat. It is good for projects with movement and detail and for applications needing a longer life expectancy.

One of the most important characteristics of vinyl is that it has "memory." Once cooled, vinyl naturally wants to return to its original form. Due to this aspect, the process used to create it produces different products with unique benefits. This distinction becomes increasingly important when exposed to heat, sunlight, and harsh environmental conditions. When choosing between the two it is best to determine to function of the vinal and proceed form there.

That is why, at Gooseneck Graphics, we take the time to understand each customer's needs and recommend the right product for the application. Gooseneck prides itself on the guarantee we promise, which is why we offer both high-quality calendered and cast as options for performance. Our goal is to offer decals that maintain their appearance, performance, and quality for years to come.