Choosing a Translucent Vinyl

By Jim Hingst

Which is Better for Backlit Signs: Cast or Calendered?

Vinyl manufacturers, such as 3M™ and Arlon, produce a broad color selection of translucent cast vinyl films for backlit signage applications. In addition to backlit building signage, other applications include taxi-top signage, mall and airport-terminal advertising, menuboards and canopy fascias.



When subjected to baking heat, cheaper calendered films can shrink and crack.

These films are formulated to uniformly diffuse transmitted light to display uniform color. Many of these cast vinyls match  pantone colors or the colors for large nationwide corporate identity programs. These very durable cast films are the top-of-the-line “Cadillac” vinyls available to sign makers.

With improvements in film technology, sign makers have other options. Today translucent calendered vinyl films are now available for “intermediate” applications. These films are designed to withstand the higher service temperatures to which these vinyls are subjected outdoors in the summer heat on the signface of a light box. Don’t expect these films to provide the same service life of cast vinyl. You get what you pay for. When you decide to use a calendered vinyl, you are buying a “Chevy” not a “Cadillac”.

In deciding whether to use either a cast or calendered translucent vinyl film, consider these factors:

• What is the application? For less demanding applications, such as menuboards and directional signs, a calendered translucent vinyl suffices. For long-term, outdoor applications, I would choose cast films.

• What are the durability requirements of the job?

• What are your customer’s expectations?

• What is the budget for the job?

User preference dictates the choice between lower-cost, calendered vinyl versus a premium, cast film. For most applications, you can’t go wrong with cast vinyl. 

However, that doesn’t preclude calendered-film usage. Newer generation, calendered, translucent films feature such improvements as color consistency and gauge control. Also, some calendered films provide improved heat stability and up to five year durability.

Because calendered films cost less than cast, they’ve become the film of choice for a wide range of backlit signage. If you use a calendered vinyl, buy one designed for the job. Although calendered films are by their very nature translucent, not all of them are suitable for backlit signage. Lower grade calendered films may look fine during the day, but inconsistencies in color and film gauge readily appear when the sign box lights up. 

I’m not saying calendered films are a bad choice for backlit applications. Better varieties have standardized thicknesses. Light-transmission discrepancies cause film-gauge variations, which appear when illuminated.

If color consistency deviates, film can exhibit blotches when illuminated. Plasticizers in cheaper calendered films can migrate to the film surface. If you screenprint or digitally print the film, plasticizing oils inhibit good ink adhesion. 

In most cases, an overlaminate should protect the print. Inks tend to be fragile, and overlaminates neutralize such hazards as UV light, air pollution and bird droppings.  

Finally, translucent films must be able to withstand high service temperatures. According to Arlon’s Chuck Bules (Santa Ana, CA) on a hot summer day, temperatures inside a light box can easily exceed 150° F. When subjected to baking heat, cheaper calendered films can shrink and crack.

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