What is vinyl and what was it made for?
I'm sure you've heard the terms PVC vinyl, cast, or calendared tossed around when researching vehicle wrap but what does it all mean? Vinyl was a blanket term used to describe polyvinylchloride (PVC) films. Almost, if not all, vinyls are made of a pvc polymer, the only difference is the style of manufacturing along with the mix of additives that differ between brands.
Cast Manufacturing
Cast materials are made as a liquid mixture, similar to paint, poured onto an adhesive layer. They tend to be thinner, more flexible, and in general last longer than calendared films. They're easier to install and require little experience to install. Despite its benefits, cast films are much less cost-effective, lack the same color selection that calendared films haves, and have finishes only as smooth as the backing is able to be.
Typical Cast Vinyl Manufacturers:
- 3M
- Avery Dennison
- Oracle
- KPMF
Calendared Manufacturing
Calendared materials differ in that the mixture of additives and polymers are kneaded and spread onto the adhesive layers and rolled. Similar to a pasta press, the rollers squeeze and flatten the sheet out which introduces some stretch into the material. This makes them much more cost effective and allow for a better finish. With the creation of PET backed vinyl, calendared films can have flawless paint like finishes. Calendared films were created initially as a temporary 3-5 year solution for signs, decals, or simple flat surfaces but in recent times have evolved into much more viable materials. Calendared films are thicker and require more knowledge and experience to install.
Typical Calendared Vinyl Manufacturers:
- Inozetek
- TinyBot
- Essmo Vinyl
- TeckWrap
- EzAuto Wrap
Debunking Myths about Calendared Vinyl
Calendared Vinyl won't last as long as cast vinyl. - Calendared vinyl often use the same raw materials but don't require solvents or curing ovens. Concerns started with monomeric films early in the introduction of calendared films for vehicle wraps. With the introduction of vehicle specific and PET backed vinyl, that has changed. With perfected mixtures and polymeric plasticizers, calendared films are now more flexible as ever and can last as long as cast vinyls when taken care of.
Calendared film is harder to install. - While it does require a longer learning curve, installing calendared vinyl requires very similar installation techniques. Main concerns from customers who are used to cast films are typically related to over stretching recesses and corners without proper post-heating. This causes the vinyl to pullback as it tries to return to its original state.
All calendared film are the same. - Similar to any retail industry, many customers often associate all calendared films with generic monomeric films that don't last and often have issues less than 6 months later. Not all films use the same additives or plasticizers, these play a huge role in the end result and finish of the film. PET vinyl is at the forefront of calendared films yet; some installers still prefer paper backed materials. This does not mean paper backed films are not good, they just don't benefit from the ultra-glossy paint like finish PET is known for. Most automotive based calendared films have made the switch to polymeric additives, films still meant for temporary or architectural uses may still be monomeric.
Aren't all vinyl's the same? Cast vs. Calendared.