Paint Mask Vinyl

How to effectively use paint mask for graphic applications.

 By Jim Hingst @hingst_jim

Why paint graphics when using vinyl is easier? In truth, paint is more economical than vinyl in some cases. This is especially true when the graphics cover a very large area.

Here’s a time-tested method to faithfully reproduce a design using paint. Some old-school sign painters use opaque projectors to transmit their design onto a paper or plastic sheet. After drawing the design onto the sheet, the painter uses a pounce wheel, a tool with very sharp points that punches small holes into the sheet. Then, he tapes the sheet into place.

Tapping a pad filled with graphite — a pounce pad — transfers the pattern. Using the pounced pattern, the fabricator hand paints the graphics. This technique is still useful, but it requires a tremendous amount of skill. Very few people can hand letter with proficiency. While the picture below may look like computer cut vinyl graphics, it was painted after the pattern was pounced by Chicago Brushmaster Ron Jelinek.

Paint-mask vinyl.

If you don’t have the skill that a professional sign painter has, there is a way to paint perfect graphics that look the same from one truck to another, from year to year. You can use a specially-designed vinyl paint mask. These paint mask vinyl films utilize a removable adhesive. Paint mask is available in various colors — white and yellow are the most popular colors in the United States. Yellow mask generally performs better; it can withstand high curing temperatures during baking cycles. In other countries, vinyl-graphics fabricators use transparent paint mask.

After cutting the film in a plotter (see the picture below), the user reverse-weeds it to create a stencil. Using vinyl with a low-tack application tape, the stencil transfers to the substrate.

Some signmakers will use cheap, calendered vinyl instead of paint mask. The materials aren’t the same. If the film and adhesive don’t remove cleanly, you’ll waste time removing adhesive and fixing mistakes.

When using a laminator to adhere the application tape to the paint mask, apply low pressure (10 to 15 lbs.). Heat from thermal laminators, which varies from 90° to 100° F, helps the application-tape adhesive to flow out, especially in the winter, when shops can be cold.

When applying very large sections of cut paint mask, use a heavyweight, premium application tape with a very low-tack adhesive. A few application tapes are designed specifically for applying paint-mask vinyl. If you don’t know which tape to use, ask your distributor for a recommendation.

The application tape needs enough tack to transfer graphics, but shouldn’t pull the paint mask from the substrate during tape removal. Many painters prefer heavier application tape because it’s less likely to tear when laminating the tape to large sheets of graphics. If the tape tears, and falls onto the graphics, the vinyl stencil is trash. 

Finally, either spraypaint or roller-paint the graphics. Using paint mask is faster than pouncing patterns. You can also brush on the paint. If you add a flow enhancer, such as Penetrol, you will eliminate unsightly brush marks.

Test, Don’t Guess.

Selecting the right paint-mask vinyl for your shop is critical. Many paint masks are on the market, and they’re not all created equal. Before purchasing, test and evaluate the paint mask before production.

Some common problems that signmakers encounter with the wrong paint mask include adhesive delamination, edge lifting and “fish eyes,” which are tiny circular craters in the paint or clearcoat that form over a substrate contaminant.

When qualifying a paint mask, apply some to a test panel, spraypaint the mask as you normally would and watch what happens. If the painted graphics will be oven-cured, simulate the heat they’ll encounter.

Curing times and temperatures depend on the paint type. For example, one paint system we recently tested cured at 150° F after 20 minutes. However, some paint systems require higher temperatures and longer curing times, whereas others need only air drying. Test the paint mask with every system you use so that all components are compatible.

If you apply paint mask to a painted surface, the paint must be thoroughly cured. If it doesn’t, the paint’s solvents will likely outgas and react with the mask’s adhesive. These solvents can turn the adhesive into a gooey mass that leaves a residue when removing the paint mask.

Installing paint-mask film is much easier than applying regular vinyl. If a wrinkle or bubble appears in the film, don’t worry. Mistakes repair easily with a little masking tape.

When painting vehicle graphics, just apply the paint mask over obstructions. After carefully removing the application tape, squeegee all paint-mask edges again.

Application Tape.

Application tape is self-wound. The tape’s paper backing picks up minute amounts of adhesive. As you squeegee paint mask in place, you may potentially transfer some adhesive to unmasked areas, which, if left, contaminates the paint. To prevent this, use a low-friction sleeve on your squeegee. Like a magnet, the sleeve picks up adhesive particles and prevents substrate contamination.

Be sure the mask’s edges fit tightly against the surface. If it doesn’t, paint will blow back underneath. Where the vinyl lifts or tents at the edges, slit the film with an X-acto® knife. Be careful not to cut the substrate surface.

After reapplying the paint mask, use only premium masking tape to clean up any dirty edges. It makes no sense to save a few cents buying a cheap tape; there are no shortcuts to quality and value. Some cheaper masking tapes allow paint to bleed through.

After applying the paint mask vinyl, sand the substrate surface with 500- to 1,000-grit sandpaper before painting. Sanding roughs the surface, promotes good paint adhesion and minimizes defects. Use an air hose to blow off paint dust. Then, wipe the surface clean using a tack cloth. 

After the paint mask is applied, the vehicle is painted. After removing the masking material, the coach is clear coated. 

Also, the paint mask vinyl may pick up silicone from the release liner and transfer it to the painted substrate. If you clearcoat the paint after masking, fish eyes can appear wherever silicone contaminates the paint.

Although silicone particles commonly cause this problem, particles of dust, wax and oil may also contaminate the surface. That’s why the substrate must be perfectly clean before paint or clearcoat applications, especially if what’s painted is very expensive. Repainting to fix a mistake is a costly remedy.

Paint job completed

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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. 

Slides of Jim's Artwork

© 2016 Jim Hingst