Puckering & Tunneling Tape

Tunneling of the application tape off of the release liner can cause sign makers headaches – especially when the graphics are rolled and shipped to a customer across the country. Here’s the problem. If the tape tunnels on the release liner, it can travel over the graphic. When this happens, it is virtually impossible for the customer to reapply the tape so that it is flat again against the vinyl graphic without causing a wrinkle.

At RTape we have tried to minimize tunneling by developing our Conform® Series of application tapes. The Conform® products feature RLA® Release Liner Adhesion, which allow these application tapes to stick to slick release liners.  

The development of the RLA® adhesive additive reduced the problem of tunneling.

With the development of the RLA® adhesive additive, the problem of tunneling was reduced, even when graphics are rolled. Note that I said “reduced” and not “eliminated”. Puckering and tunneling of the application tape over the surface of the release liner and graphic can still occur for a number of reasons.

Among these reasons, humidity can certainly contribute to application tape problems. This is especially the case, if the graphics were fabricated in an air conditioned environment, where the humidity is low, then taken outside, where the humidity in the summer air is high. The moisture in the air condenses on the cold surface of the application paper, just as moisture condenses on the outside of a glass containing a cold, refreshing adult beverage. As the application paper absorbs the moisture, it grows at such a rate that it pulls away from the release liner. When this happens, no amount of RLA® additive will allow the tape to lay flat on the liner.

The biggest factor in tunneling is mechanical stress. In the lamination process, you need to take care to avoid stretching the application tape.  Stretched tape usually shrinks, causing tunnels as well as causing the vinyl graphic to curl.

The best way to apply application tape is with a laminator. This is how fleet graphics screen printers premask their graphics. And it’s the reason that they rarely have tape issues such as tunneling. If you can afford one, a laminator is a worthwhile investment for your shop.  If the laminator is set up properly, you will apply application tape to graphics with a minimum of wrinkles, bubbles and tunneling.  Equally important is that you will apply the application tape with low mechanical stress.

If your laminator has a heated roller, applying a little heat (100⁰F or 38⁰C) when laminating the tape to the graphic  can cause the adhesive on the application tape to flow out better and create a better bond to the graphic. This can also help reduce the problems of a tape lifting off the surface of the graphic and creating a tunnel.

The next best alternative is to buy some type of application tape dispensing system. I have several. These include the WEBERmade tape dispenser and the ProRoll Application Tape Roller from Image One Impact.

The WEBERmade system bolts right on to your workbench with a couple of clamps. What I like about the machine is that it has a clutch or tension control knob, which allows you to adjust the unwind tension of the roll. Be careful, though. If you over-tighten the unwind tension, you can stretch the application tape as you laminate it to the cut vinyl graphics. What happens next is that the tape wants to stretch back to its original shape. As this happens, the application tape pulls away from the liner. If you look at the picture below, all of the tunnels, which have formed, are all across the web. This suggests stretching and contraction in the web direction.

Humidity and mechanical stress are two possible causes of puckering and tunneling.

The ProRoll  Application Tape Roller works differently.  It is a handheld device that allows you to simply roll the application tape over your graphics. Tape is applied to the vinyl graphics smoothly, with very low mechanical stress. And that reduces the likelihood of tunnels and curling graphics.

The ProRoll Application Tape Roller from Image One Impact.

One final word. If you are having problems with your application tape, call you sign supply distributor. You can also call RTape direct at 800-440-1250 or 908-  We will make every effort to answer your questions quickly and efficiently. 

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Vinyl Application Videos

Squeegee Technique. Nothing is more basic in vinyl application than the squeegee. But some squeegees work better than others. And there are right ways and wrong ways to use this simple tool. This video clip reviews squeegee selection, squeegee care and squeegee technique. Click to Link

Wet Applications. Dry applications are typically recommended for most vinyl applications. For those exceptions to the rule, this instructional video explains the right way to perform a wet application. Click to Link

Application of Window Graphics. Installing vinyl graphics on glass can be challenging, because the adhesive aggressively grabs onto this high energy surface. Repositioning graphics on window is generally difficult, if not impossible. This instructional video explains how to dry apply window graphics right the first time. It also describes the necessary steps required for surface preparation. Click to Link

Transferring Frosted Window Graphics Films.  Because frosted window films are highly textured, transferring cut vinyl graphics can be problematic. This video provides direction in selection of the right application tape and how to apply these films quickly, easily and without problems. Click to Link

3-Step Surface Prep. This instructional video describes how to properly clean the surface of a vehicle before applying pressure sensitive vinyl graphics to a trailer or doing a full wrap of a car or van. This three step surface prep involves detergent washing, solvent cleaning and a final wipe down with IPA. Click to Link

Vinyl Application Over Rivets. Applying vinyl graphics on vehicle surfaces with rivets is challenging for most sign makers. Vinyl failures to these surfaces are all too common. This video demonstrates some tips and procedures, used by professional decal installers, which will make these demanding applications easier and more trouble-free.  Click to Link

Vinyl Application to Corrugations. Learn how to apply vinyl graphics to corrugations in a relaxed state. Forcing films into the valleys of corrugations puts too much mechanical stress on the film. Sooner or later, the vinyl will lift or tent in valleys. Click to Link

Applying Air Egress Vinyls. Vinyl films with air egress release liners have almost eliminated bubbles and wrinkles from applied graphics. Air egress release liners with their highly textured surface structure are problematic. Not much will stick to these liners other than the vinyl film. At RTape our best premask solution for air egress liners is a special Conform® tape called 4761RLA. Click to Link

About Jim Hingst: After fourteen years as Business Development Manager at RTape, Jim Hingst retired. He was involved in many facets of the company’s business, including marketing, sales, product development and technical service.

Hingst began his career 42 years ago in the graphic arts field creating and producing advertising and promotional materials for a large test equipment manufacturer.  Working for offset printers, large format screen printers, vinyl film manufacturers, and application tape companies, his experience included estimating, production planning, purchasing and production art, as well as sales and marketing. In his capacity as a salesman, Hingst was recognized with numerous sales achievement awards.

Drawing on his experience in production and as graphics installation subcontractor, Hingst provided the industry with practical advice, publishing more than 150 articles for  publications, such as  Signs Canada, SignCraft,  Signs of the Times, Screen Printing, Sign and Digital Graphics and  Sign Builder Illustrated. He also posted more than 325 stories on his blog (hingstssignpost.blogspot.com). In 2007 Hingst’s book, Vinyl Sign Techniques, was published.  Vinyl Sign Techniques is available at sign supply distributors and at Amazon. 

© 2016 Jim Hingst