Decals are a common sight at many businesses. They are often used for product branding and as part of marketing campaigns.
The process of making decals begins with the substrate, or base material.
Common Substrates for Decals
- Calendared vinyl is the most common type of substrate used for decals. It is a vinyl passed through rollers to create a thinner, more pliable material. Calendared vinyl is less expensive and can be cut into shapes and letters more easily than other types of vinyl.
- Cast vinyl begins as a liquid mixture. By gradually adding heat, it gains a fabric-like consistency. Once it has cooled, it can be cut and shaped. As a result, cast vinyl is more durable than calendared vinyl and can withstand more wear and tear.
- ControlTac™ vinyl is a pressure-sensitive material applied to surfaces without heat or water. This vinyl has channels which release air, so no bubbles form during application. It provides a glossy, opaque look while being easy to remove. This long-lasting vinyl is often used for car and window decals.
- Carbon fiber vinyl is made with a polyester base with a carbon fiber pattern printed on top. This gives the decals the appearance of carbon fiber while being lighter and stronger than steel.
- Metallic vinyl has a base made of polyester or PVC. This material is shiny and reflective and appears to be made of metal. It usually comes in gold and silver but can also be found in other colors.
Design and Printing
After the substrate has been created, it is time to print the decal. The decal design is first created in a vector graphic software program, such as Adobe Illustrator. Once the design is complete, it is then exported to a vector file format the printer can read.
The printing process is done in two ways: screen printing and digital printing.
Screen printing involves utilizing mesh screens to transfer ink onto the substrate. The vinyl is placed on top of the screen, and ink is pushed through the holes in the screen onto the vinyl.
Digital printing uses a printer to transfer the design onto the substrate. The vinyl is fed into the printer, and the design is printed. This process is faster than screen printing and produces high-quality results.
Cutting the Decal
Once the decal has been printed, it’s time to be cut.
Die-cutting machines are a common option. These machines use a die, or metal template, to cut the vinyl. The die is placed on top of the vinyl, and the machine cuts around it.
After the decal has been cut, it is then ready to be applied to the desired surface. Decals can be applied to many surfaces, such as windows, walls, floors, cars, and glass.
At FASTSIGNS® of Boise, ID, we make custom decals for businesses in the Ada County area. Visit us today to start on your custom sign package.
