Stickers and decals are an indispensable means of marketing for some businesses. If you are considering decals as a means of marketing, or if you’re just curious about how decals are made, this article might be of value. Knowing how decals are made will help you understand your options, communicate more effectively with your sign company and minimize production costs.
Design
As with many types of signage, decals begin with a design that incorporates the graphic elements and message you want to present. Decals can be digitally printed in full color, so consider how to use color to enhance your message in your design. As with most signage, vector art is preferred. If bitmap images are used, be sure to use sufficient quality images:
- Avoid using JPEG (JPG) images. If JPG is used, favor higher quality over smaller file sizes.
- Avoid using images captured from the internet. This type of image is intended for screen display, compressed, small and low resolution.
- If uncertain about image quality, closely review the image in an image editing application by increasing display magnification or zooming in and panning around the image.
Contour Cut
Though a decal may be in a simple geometrical shape, they can also be contour cut, following the edges of your design regardless of shape as seen in the example below:
If your decals are to be contour cut, discuss your requirements with your sign company before completing your design. The creation of this contour cut line is generally easier for vector based art. Though bitmap art can also be contour cut, this requires a means of detecting the outline or edges of your image. To facilitate edge detection, your design must have sufficient contrast between the art and background where the background is the portion to be cut away. Your sign company may request that artwork be submitted in a format (such as .PNG or Photoshop .PSD) that supports transparent backgrounds. Expect a modest design fee for adding the contour cut line to your artwork. The time required and associated fee can be minimized by checking with your sign company in advance.
Printing
Once your design has been completed and submitted, your decals can be printed. Most typically, your decals will be printed on adhesive PVC. This type of media is available in a number of grades and weights. Discuss the intended usage with your sign company to determine the appropriate type of media. In general, heavier weight media is easier to handle and install bubble free. For installation on flat surfaces only, there may be more options than when installing on curved surfaces.
The printable media comes on a roll with adhesive PVC adhered to a slick backing sheet. Decals will be printed in rows and columns to make the best use of the width of the media roll as seen below.
If lamination is required, this matrix of decals will typically include registration marks at the bounds of the print area. These registration marks are required for the printer to be able to contour cut the decals. Lamination requires that the media be removed from the printer. The registration marks denote the art bounds so that the laminated print can be run through the printer again for contour cutting. An optical scanner on the printer will find the registration marks at all 4 corners, and even compensate for minor media skew to ensure cut accuracy.
Lamination
Lamination protects the printed surface of your decal and adds additional body that makes installation easier. Lamination can add some protection from UV rays that will fade colors in your decals if exposed to sunlight. Unless cost is the primary consideration, lamination should typically be included.
Lamination will invariably add to the cost and production time of decals. Depending on the print technology used, your printed decals may need to sit or “gas out” for 24 hours before being laminated. After being laminated, your decals can be loaded on the printer again to be contour cut.
Weeding and Trimming
After being printed, laminated and contour cut, your decals are “weeded”. Weeding is the process of removing the background or unwanted area around each contour cut decal.
Once weeded, your decals are cut into strips, then each strip is trimmed in a rectangular shape around each decal. The finished product will consist of contour cut adhesive decals on a rectangular piece of backing paper. Bending the backing sheet backward, away from the decal will ease removal of the sticker from its backing sheet.
About Spectrum Signs
Spectrum Signs is an independent, locally owned, full service sign manufacturing company located in Mission Viejo, California. By understanding your business needs, we can better advise you through the technical process of selecting the right materials and production process to suit your intended application.
We are affiliated with over 240 independent sign companies with access to resources nationwide. This affiliation provides significant discounts from sign suppliers, and allows us to offer competitive pricing without compromising in quality and service.
For more information, contact:
Spectrum Signs
23382 Madero Suite L
Mission Viejo, CA 92691
(949) 297-3800
