In the world of vehicle graphics, durability is one of the key components in achieving customer satisfaction and professional success. It goes without saying that the graphic appeal of the wrap, the precision of its application and the “wow factor” are the elements that initially fill customers with a sense of instant gratification. However, if durability isn’t a part of the delivered product, that sense of satisfaction won’t last for long. People want their investments to endure, and that also goes for the investments they make in marketing through vehicle wraps.

Since that is the case, it is essential for those of us who earn a living by building a reputation for being the best vehicle wrappers in the business, to make sure that we are using the best products and the best methods in order to ensure the maximum durability of the wraps we create. Durability comes down to using quality materials with superior adhesives and applying them professionally. Let’s take a closer look at the materials used in vinyl vehicle wraps.

FILM TYPE 1: CALENDERED
Generally speaking, vehicle wrap films are produced as either calendered vinyl or cast vinyl products. Calendered vinyl film begins its life as a combination of ingredients like vinyl particles, polymers, plasticizers and other additives, some of which are designed to add pigment or reduce UV vulnerability. These ingredients are heated and melted. After that, these materials endure an extrusion process that essentially produces a flat sheet of calendered vinyl film. To put it very simply, calendered vinyl starts as a solid and is formed, stretched and rolled out to become film for vehicle wrapping. As a result, this type of vinyl film carries some inherent difficulties when it comes to applying it with precision. Chief among these difficulties is the memory of calendered vinyl.

Since calendered vinyl starts as a solid it retains some of its memory concerning what it was before it was made into wrap film. Calendered vinyl films undergo substantial stress during production due to the heating, stretching and rolling processes involved. The outcome of all of this stress to the material, and the memory issues mentioned, is simple to understand. Calendered vinyl is less expensive but it does not lie down as easily when it comes to the fine points of wrapping a vehicle.

Trying to lay calendered vinyl over breaks in contour such as seams, curves, rivets and all of those other little interesting details can prove challenging while wrapping a vehicle with precision using this material. Of course it can be done, and some people do it very well, especially for flat or short-term applications. However, it is important to remember that wrapping a vehicle with calendered vinyl requires using very aggressive adhesives since the stress placed on this kind of vinyl during production often results in long-term shrinkage. And the more aggressive the adhesive, the more difficult it is to work with. If an adhesive is too aggressive, it becomes nearly impossible to adjust the vinyl film once the adhesive has made initial contact with the surface. While many adhesives are now designed with air egress channels making for fewer bubbles and a better look, the aggressiveness of the adhesive still impacts how easy it is to work with.

As far as removing calendered vinyl film from a vehicle wrap is concerned, these aggressive adhesives make that process much more difficult. When using any kind of adhesive in the process of producing a quality vehicle wrap, adhesiveness and clean removal have to be weighed in the balance. Adhesion and clean removal are impacted by the method of application, whether it is a cold application process or a hot one. So, all of these issues have to be carefully considered when determining the durability of any quality vehicle wrap.

FILM TYPE 2: CAST
Cast vinyl film is a different story. The cast film used in vehicle wraps differs from calendered vinyl film in that it begins as a liquid rather than a solid. Cast films are created by fusing vinyl particles together. This process is fairly stress-free and results in limited shrinkage. The process of making cast vinyl begins with various ingredients that are poured into a vat or mixing churn. These ingredients are added in a specific order and at a specific rate of speed in an effort to achieve the perfect balance and consistency in the mixture. After all of the ingredients are mixed together at the appropriate speed, the liquid is then poured in a very thin layer onto a casting sheet that resembles a web. This sheet is passed through a series of ovens at specific temperatures and at very precise rates of speed. This regulated “baking” process causes solvents to evaporate and leaves a solid film behind. The film is then gathered onto large rolls for the adding of adhesives.

One of the biggest differences between cast vinyl film and calendered vinyl film is that cast film enters into its existence by being poured directly onto the casting sheet. It forms in a relaxed state. There is no stretching involved in the creation process of cast vinyl film. As a result the stability of the vinyl is greatly enhanced. This very stable product resists shrinking and is generally more durable than calendered vinyl. Cast vinyl film is considered a premium product that results in long-term performance and satisfied customers. Due to its properties, many manufacturers recommend using only cast vinyl film when both durability and customer satisfaction are key concerns.

SIDE-BY-SIDE ANALYSIS
The end result of all of these factors is that calendered vinyl film is an inexpensive and economical product that can be used for short-term vehicle wrapping. However, calendered vinyl film lacks the durability of cast film. Calendered vinyl film wraps can look good for a time but susceptibility to shrinkage and other issues of the material don’t make calendered vinyl the best long-term solution for outdoor wraps.

An important element of cast vinyl is that it is a much thinner film. This increases the film’s conformability and results in a finish that is hard to distinguish from paint (usually about 2-mils in thickness). Since cast vinyl films are typically more highly rated for durability and performance than calendered vinyl films, manufacturers can offer more substantial warranties on these films. Of course, warranties differ from manufacturer to manufacturer, but by and large calendered vinyls don’t compare to cast vinyl films when it comes to the warranties involved. Customers who frequently change the graphics on their vehicles choose calendered vinyl film for its affordability, not necessarily its durability.

Resistance to shrinkage is another factor that impacts and increases the warranties offered on cast vinyl film. Since shrinkage isn’t such a big issue with cast vinyl film, it has a tendency to be more durable and easier to work with. Remember, shrinkage creates the need to work with more aggressive adhesives to keep the vinyl wrap film from moving after application. Applications with cast film are often done with more user-friendly adhesives. The result is an application that places less stress on the film, resulting in cleaner removal when necessary and consequently increased outdoor durability of the wrap.

There are ways to prolong the life of film by pairing up vinyl with an overlaminate to produce a desired finish. While using overlaminates adds to the durability and appearance of a good wrap, it’s important to remember to use the right overlaminate with the type of vinyl being applied to the vehicle. For example, placing a calendered overlaminate on cast vinyl film will not fool the vehicle. The calendered overlaminate will still try to lift away from the vehicle and could even take the cast vinyl film with it. So don’t try to take short cuts with overlaminates.

THE PERFORATED ADDITION
A popular type of film being used more and more often in the vehicle wrapping industry is perforated window film. This type of film contains small perforations in the material that allow for visibility through clear surfaces, making it a very useful material for wrapping storefront windows and even vehicle windows. While this technology is innovative and exciting, it is important to remember that the vinyl that is being perforated in order to create this product still falls into one of two categories: cast or calendered. All of the issues discussed earlier will necessarily impact the durability of perforated vinyl film.

Most of the perforated films being offered on the market right now are made with calendered vinyl film. Perforated cast film that combines the usefulness of perforated film with the durability of a cast vinyl is slowly starting to become available. This particular film seems to be outperforming the others and most likely is a peek at the future of window film. 

Travis Haremza, owner of Midwest Wraps in Tulsa, Okla., has been working with vehicle graphics for over 10 years. During that time he has completed several hundred vehicle wraps while using a number of different vinyl films.

Haremza opts for cast vinyl while wrapping around complex curves which exist in every vehicle including compact cars, SUVs, Hummers and trucks. He says, “There are a couple of areas that require a bit more finesse [for those vehicles]. Some companies don’t like doing them due to lack of experience or not knowing how to address these areas.”

However, when using the correct films and adopting a thorough approach, much of that fear to wrap is alleviated. Haremza offers up five more tips which can help extend the life of cast films while achieving a quality wrap and keeping customers happy.

1. Prior to installation, prepare the vehicle for a wrap by making sure the “live area”, or the area to be wrapped, is free of particles. Take the correct procedures by washing the vehicle 24 hours prior to installation and then using Isopropyl rubbing alcohol to scrub away any excess debris. The next step that is taken is to wipe rocker panels and fender wells with Xylene, this cleaning agent will remove tar and exhaust residue. Once the tar and exhaust are removed you will want to wipe the vehicle with prep solvent. The purpose of the prep solvent is to remove oils, wax, grease, and silicone. The final step in preparing the vehicle for installation is to repeat wiping the vehicle with Isopropyl rubbing alcohol. This will allow the vinyl to bond cleanly to the vehicle’s surface and ensure that you have some ground if ever a warranty claim is needed.

2. To provide additional adhesion, add tape primer to areas on a vehicle that are subjected to the most stress and let it dry for five minutes before applying graphics, but make sure that you have the vinyl installed in the primed area within 45 minutes. Due to the short time window allowed while working with tape primer it is best to only prime the areas that you can have installed within that specific time. Typical areas for primer are around door handles, convex/concave areas and along the edges of ending panels.

3. Match your films with the appropriate overlaminates for warranty purposes, for example using a film and overlaminate from the same manufacturer will keep the integrity of the film’s warranty. If graphics fail prematurely, film manufacturers usually cover the material over a specific time span so long as it is used as intended and you have prepared the vehicle properly prior to installation.

4. When possible, provide seamless installations, which means wrapping a vehicle without unnecessary breaks in the graphic panels. Use only natural breaks, between the doors for instance, to hide a seam and insert a new graphic panel. Make sure all of your materials are getting tucked inside of the doors and body panel seams are free of wrinkles. This will help ensure that the graphics will be less likely to start curling or lift around the doors’ edges and/or body panel seams.

5. Lay the vinyl down completely and always post-heat your wrap. The post-heating step is the single most important thing that most installers forget, don’t know or just don’t take the time to do. It will help to “set” the adhesive and keep your graphics where you stuck them, especially over concave or in convex areas. You don’t want the vinyl to return back to its original shape and post-heating makes a huge difference.