Plotter Cutting VinylEfx and EZ Erase Films

To avoid problems when cutting VinylEfx® and EZ Erase™ vinyl films, follow Jim Hingst's detailed instructions covering the basics of plotter cutting.

Plotter Blade Angle.

VinylEfx®  and EZ Erase™ vinyl films cut as easily as most  glossy, white calendered vinyls.  For best cutting results, use a sharp 45° plotter blade at slow cutting speeds with swivel type of cutters. Optimal cutting pressures vary depending on plotter type and blade sharpness. 

Cutting thicker vinyl films, such as RTape’s ChalkTalk® or reflective vinyl sheeting will require a blade with a much sharper angle, such as a 60° plotter blade. Remember that when you change blade angle, you will also need to change the offset value. After changing  a plotter blade with different angles and adjusting the offset value, you should always perform a test cut.

Adjusting Blade Depth. 

One of the first adjustments that you should make in setting up your plotter is setting the blade depth. One popular rule of thumb is to set the depth of the blade so it barely extends past the end of the blade holder at approximately half the depth of a credit card. As far as rules of thumb go, this is a good general rule, when you are cutting cast vinyl films and heat transfer material.

While this rule may work for many applications, don’t expect it to work in all cases. Unfortunately, one setting doesn’t fit all media, because media thickness varies greatly.  The thickness of RTape’s VinylEfx® and EZ Erase films is approximately 2.7 mils for the facestock with a mil of adhesive. RTape’s  ChalkTalk® is much thicker. It is a 6.5 mil modified styrene film with a mil of adhesive.

A more precise setting is to adjust the blade to a depth that is at least as great as the thickness of the media that you are cutting. Getting the depth just right without highly specialize equipment can be a frustratingly tedious process of trial and error. Setting the blade depth much greater than necessary can result in dulling the blade faster, especially when you are cutting films that utilize a polyester release liner.  

One quick test to determine if the blade is adjusted to the proper depth (prior to installing the blade holder in the plotter) is to perform a manual test cut. This manual test is simply a matter of grasping the blade holder in your hand, and dragging the blade across the media in an upright position, perpendicular to the surface. The blade should cut completely through the film and only slightly score the surface of the carrier or release liner.  You should not cut so deeply that you can feel the cut lines on the backside of the carrier. Adjust the blade in its holder according to your test cut results. See Diagram A below.

Diagram A.

Adjusting Blade Offset.  

Blade offset is the distance between the tip of the cutting blade and the center of the blade. This distance will vary depending on the angle of the blade used. Different blades have different offsets.

For accurate cuts, you must adjust your plotter’s offset setting to the manufacturer’s recommendations. For example, the correct offset value for a 45° blade, may be 0.250 mm. After changing to a 60° blade, you may need to change the offset to 0.100mm.

In many cases this setting is frequently ignored.  Improper settings are not difficult spot. A telltale sign that the offset value is too low is that the outside corners, when cutting a square, are rounded off. Conversely, if the corners protrude or end in a spike, the value is typically too high.  If you cut a circle, and the offset value is incorrect the starting point of the cut will not meet up accurately with the finishing point. The result is that the circle will not close completely.

Downforce. 

Downforce describes the amount of pressure (generally designated in grams) that is applied to the cutting blade. Cutting polyurethane heat transfer films may take as little as 70 to 80 grams of pressure or less.  When cutting RTape’s VinylEfx® or EZ Erase™ films the typical downforce pressure is between 135 grams and 165 grams. Downforce pressure, of course, will vary from one plotter type to another and depend upon the sharpness of the blade.

The ideal setting is to use the least amount of force to accomplish the job. If the plotter is not adequately cutting the media, first check the cutting depth. If that is set properly, adjust the downforce. In many cases the remedy is to decreases not increase the cutting pressure.

Cutting Speed.  

When plotter cutting VinylEfx® or EZ Erase™ films, you will most likely need to slow your cutting speed.

Conditioning the Media. 

Temperature and humidity can great affect the layflat stability of most pressure sensitive vinyl films, especially when the release liner is paper. If you just brought in a roll into your shop from extreme cold, you may need to give it time to come up to temperature before using it.

Humidity is another major factor, because a  paper release liner can gain or lose moisture.  This can cause the liner to grow or shrink, resulting in curling of the material. For this reason, you may need to condition the media before using it allowing it to adjust and stabilize to your shop environment.

Test Cut.  

After you load the media in your plotter and before you run a job, do a test cut. Check that the depth of the cut is completely through the media but only lightly scoring the carrier or release liner. Make sure that you cannot feel the cuts on the backside of the carrier. Cutting too deeply is as much of a problem as not cutting deeply enough.

If you are cutting square shapes, one inside another, as part of your test cut protocol, check that the corner cuts are precise. And if you cut concentric circles, see that the lines meet cleanly after the blade makes a full circuit.

Troubleshooting Plotter Problems. 

Plotter problems will occasionally arise.  When they do, use the tips in this article to troubleshoot the problem.  Through a systematic process of elimination, check the most likely causes. If you can’t solve the problem, ask for help.  First, call your distributor.  If he can’t answer your questions, he may refer you to the plotter manufacturer.

For drawing on EZ Erase Films use

Chalk Ink 6mm Classic Wet Wipe Markers

● Waterbased pigment ink.

● Removes easily with ammonia based cleaner.

● Non-toxic; no harmful solvents such as xylene.

● Works on a wide range of non-porous surfaces.

Slides of VinylEfx films used for store graphics.

NEW INSTRUCTIONAL VIDEOS.  Five new videos have been added to RTape’s  YouTube channel. The following is a description of the new 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 here to view the Squeegee Technique video.

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 here to view the Wet Applications video.

Introducing AT65. Installing multiple color overlays with a paper application tape is not much easier than driving in the dark without your headlights. For these challenging applications, RTape developed its AT65, the universal high tack film. This video clip explains the features and benefits of this remarkable new film application tape. Click here to view the Introducing AT65 video.

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 here to view the Application of Window Graphics video.

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 here to view the Transferring Frosted Window Graphics Films video.

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.

Slides of Jim's Artwork

© 2015 Jim Hingst