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When choosing vinyl for signage or vehicle wraps, knowing the difference between cast and calendered vinyl can significantly impact the outcome of your project. Additionally, within calendered vinyl, the difference between polymeric and monomeric vinyl plays a crucial role in determining durability and application flexibility.
Cast vinyl is manufactured through a liquid casting process, producing a thin, flexible film that is free from internal stress. This lack of mechanical stretching means that cast vinyl has no “molecular memory”, giving it its unique ability to conform to complex shapes like curves, rivets, and corrugations. It is known for its excellent conformability and dimensional stability, which make it ideal for long-term applications such as vehicle wraps and outdoor signage.
✔ SUPERIOR CONFORMABILITY
Cast vinyl can easily stretch and conform to intricate surfaces without shrinking over time.
✔ DURABILITY
With outdoor durability lasting up to 12 years, it offers excellent UV resistance and colour stability.
✔ MINIMAL SHRINKAGE
Since cast vinyl doesn’t retain molecular memory from manufacturing, it remains dimensionally stable for years.
Calendered vinyl is made by rolling PVC through heated rollers, resulting in a thicker, more rigid material compared to cast vinyl. While calendered vinyl is more affordable, it has limited conformability due to the internal stress introduced during manufacturing. Calendered vinyl comes in two types: polymeric and monomeric, each with different performance characteristics.
✔ COST-EFFECTIVE
Calendered vinyl is more affordable than cast vinyl, making it a budget-friendly option for short to medium-term projects such as promotional signage.
✔ DURABILITY FOR SIMPLE APPLICATIONS
Polymeric calendered vinyl offers decent durability (up to 8 years) for flat or slightly curved surfaces, making it suitable for applications like window graphics and indoor signage.
✔ EASE OF HANDLING
Due to its thicker structure, calendered vinyl is easier to handle and apply especially for flat surfaces or beginners in vinyl in installation.
Polymeric vinyl uses long-chain plasticisers, which bind more effectively to PVC molecules, resulting in greater durability and flexibility. It offers moderate conformability, making it suitable for medium-term outdoor applications like low-curved vehicle wraps and signage.
Polymeric vinyl is more resistant to shrinkage compared to monomeric vinyl, with a lifespan of up to 8 years
In contrast, monomeric vinyl contains short-chain plasticisers, which migrate out of the material over time, making it more prone to shrinkage and cracking.Â
Monomeric vinyl is best used for short-term, flat applications like promotional decals or indoor signage, with a lifespan of 1 to 3 years.
When considering calendered vinyl, knowing the difference between polymeric and monomeric vinyl will help you make the right choice for your specific needs. Polymeric vinyl offers better flexibility and longer-term performance, while monomeric vinyl is suitable for short-term, budget-friendly projects on flat surfaces.
Choosing the right vinyl comes down to understanding the difference between cast and calendered vinyl, as well as the difference between polymeric and monomeric options within calendered vinyl. For high-performance, long-term applications, cast vinyl is unmatched in conformability and durability. If you’re looking for a more economical option, polymeric calendered vinyl strikes a balance between cost and flexibility, while monomeric calendered vinyl is best for short-term, flat applications.
By aligning your project’s needs with the right type of vinyl, you ensure optimal performance and longevity, whether for vehicle wraps, signage, or promotional decals
References
All Print Supplies, n.d. Which Type of Vinyl? The Pro's & Cons' Of Calendered And Cast Films. [online] Available at: https://allprint.co.uk [Accessed 17 October 2024].
Printing United Alliance, 2016. Ask the Expert: Cast vs. Calendered Vinyl. [online] Available at: https://printing.org [Accessed 17 October 2024].
American Sign Products, n.d. Cast Vs. Calendered Vinyl Film: Which Is Best For Your Project?. [online] Available at: https://americansignproducts.com [Accessed 17 October 2024].
Graphic Warehouse, 2024. What is the Difference Between Monomeric, Polymeric, and Cast Vinyl?. [online] Available at: https://graphicwarehouse.co.uk [Accessed 17 October 2024].
Graphic Design Supplies, 2024. What is the Difference Between Monomeric, Polymeric and Cast Vinyl?. [online] Available at: https://graphicdesignsupplies.co.uk [Accessed 17 October 2024].
