Cast vs Calendered Vinyl Films

One of most common questions concern the vinyl films used for vehicle graphics. Let’s talk about the type of vinyl, as Not all vinyl films are equal!
There are two main types of vinyl: Cast Vinyl and Calendered Vinyl.

Cast Vinyl

We RECOMMEND using Cast vinyl films on your vehicle. In fact, Cast vinyl is all we use to produce our graphics.

Cast Vinyl films are produced by mixing up all the components (PVC, Plasticizers, Pigment, Stabilizers) with a liquid solvent and pouring it onto a casting sheet in paint-like liquid form. This paint-like liquid (organosol) can spread naturally on the casting sheet. Finally, it is heated and cured in a series of ovens on a conveyor belt, causing the solvent to evaporate and leave behind a solid paint-like film, usually 2-4mil (50-100 microns). The advantage of this production method is that it is produced in its natural stress-free state, so it is not susceptible to shrinking and cracking during weather changes. These films usually have a high durability rating of 5-10 years on a vertical plane. They are designated for Flat, Compound Curved, Riveted, and Deep Recessed surfaces. These films are available for both Wet-Installation and Dry-Installation methods in both wrap and non-wrap materials.

Advantages:

As zero stress is applied to cast vinyl film during manufacturing, it has a close to zero shrinkage rate.
A strong bond between the components created by the manufacturing process results in enhanced durability.
Color and structure are higher quality due to how the material is produced.
Cast vinyl is only 2-4mils (50-100 microns), so it can conform to compound curves and recesses.

Examples of Cast Vinyl Films are 3M 7125, 3M 180mc, 3M 1080/2080, Avery SC950, Avery SW900, Oracal 751/951, Oracal 970RA and equivalents.

Calendered Vinyl

We DO NOT recommend using Calendered vinyl films on your vehicle. (We will not supply graphics in calendered vinyl; please don’t ask.)

A LOT of eBay, Etsy, Amazon, and cheap online sellers use these films because they are low-cost and look good in the SHORT term.

Calendered Vinyl films are produced by extruding a heated mixture of PVC and plasticizers through a series of rollers, which flatten and stretch it until it is the correct product thickness, usually 3-4mils (76 – 102 microns). Calendered films are often referred to as Short-Term, Economy, or Intermediate films. The problem with these films is that when they are heated and cooled as the weather changes, they shrink and crack as they try to return to their pre-stretched form. These films usually have a durability rating of 1-5 years on a vertical plane. They are designated for use on flat surfaces or with simple curves.

Disadvantages:

As zero stress is applied to cast vinyl film during manufacturing, it has a close to zero shrinkage rate.
A strong bond between the components created by the manufacturing process results in enhanced durability.
Color and structure are higher quality due to how the material is produced.
Cast vinyl is only 2-4mils (50-100 microns), so it can conform to compound curves and recesses.

Examples of Calendered Vinyl Films are 3M Series 50, Oracal 651, and Avery HP700, Avery A6 and equivalents.