Hey there, Atarah here, Fusion Marketing’s Content Curation Specialist and SEO Expert. Today, I want to share an insightful chat I had with the gang about a topic that often triggers a lengthy debate in the marketing world: cast vinyl versus calendared vinyl.
I wrote an article about cast and calendered vinyl already. I started it and went back to it about 20 times, but it took me forever to figure out the ins and outs in a way that explained why there are even different vinyls in the first place. While I know a ton about my corner of the marketing world and can research with the best of them, sometimes even I get a little lost when it comes to the differences between similar material types.
So, since I’ve already spent at least an entire day searching for the best information on the topic and still didn’t feel like I had a good enough grasp, I dropped the subject at a meeting to see if they’d be able to give me a push in the direction I needed.
Lucky for me, I have fantastic teammates with tons of knowledge!
Lucky for you, I’m here to share those insider tips with you!
So, What’s the Difference Between Cast and Calendered Vinyl?
When I asked about the big differences between cast and calendared vinyl, Mark, our Graphic Designer, gave a quick rundown. He highlighted the distinct production processes and how these result in differing characteristics.
Production of cast vinyl involves pouring liquid vinyl onto a moving sheet and baking it to form the desired thickness. This results in a very thin and flexible sheet, allowing for minimal stretching or shrinking when applied to curved surfaces. On the other hand, calendared vinyl is made by pressing solid sheets of PVC through heated rollers, resulting in a thicker and less flexible material.
The significant distinction between these two types of vinyl is that cast vinyl has superior conformability and can be applied smoothly to complex surfaces like vehicle wraps or brick walls. Calendared vinyl, on the other hand, works best for flat surfaces or windows.
But I wanted to dive deeper into what these differences mean in practical terms. What does this all mean for you? What projects should you use cast vinyl for versus calendared? And what are the risks involved in using the wrong type of vinyl?
Let’s find out!
What’s the Longevity of Vinyl?
One of the big things that you’ll hear time and time again is that cast vinyl lasts longer than calendared vinyl. But Mark had some interesting thoughts on this topic: “It all depends on how you take care of it.”
He went on to explain that if a vehicle with either a cast or calendered vinyl design was left out in the sun constantly, without shelter or garage storage, then there would be an increased chance of damage to the wrap’s adhesive layer. He added, “Vinyl can start peeling and cracking in certain areas if it’s not taken care of properly.”
So, while cast vinyl may have a longer lifespan overall, proper care and maintenance play a significant role in the longevity of any type of vinyl. When choosing the right type of vinyl for your project, consider factors like exposure to sunlight, extreme temperatures, and harsh environmental conditions.
Overall, cast vinyl can last up to 10 years, while calendared vinyl typically lasts for around 3-5 years. However, with proper care and maintenance, both types of vinyl can last much longer.
Which Vinyl Type Is More Durable?
When it comes to durability, John (our CEO) chimed in with his expertise! He explained that cast vinyl is ideal for long-term projects exposed to extreme weather conditions as it’s less likely to fade compared to calendared vinyl.
However, calendared vinyl is a more cost-effective option if you plan to use vinyl for a short-term project like event signage or promotional banners.
The Ease of Removal: Is It a Factor?
I raised the concern about potential damage to surfaces, specifically vehicles, during vinyl removal. I know that when my husband bought a food truck that had been baking in the Arizona sun for years, he had to use a heat gun and a lot of patience to avoid damaging the paint
Mark had some great insights on this topic as well. He explained that removal is definitely easier for cast vinyl than calendared vinyl due to its thinner and more flexible nature. Cast vinyl has a much more delicate release liner compared to calendared vinyl. This means that during the removal process, there is less of a chance of damaging the surface underneath cast vinyl than calendared vinyl. However, calendared vinyl may leave behind adhesive residue or even pull off paint if not removed carefully.
He also stressed the importance of proper installation techniques for both types of vinyl to minimize any potential damage during removal.
John quickly pointed out that damage is rarely an issue unless the vehicle’s paint job is subpar, the paint hasn’t had time to cure properly, or the vinyl is left on for longer than it should have been and poorly maintained.
Surprisingly, Mark and John even agreed that sometimes, removing magnets from a vehicle can cause more damage than removing vinyl due to the potential for surface rust or dirt buildup.
Application Considerations
When I asked about the application process for these two types of vinyl, Mark and John explained that another key difference between cast and calendared vinyl is the application process.
According to John, applying cast vinyl requires a lot more skill and experience than calendared vinyl. Cast vinyl is very thin and delicate, making it challenging to apply without damaging or stretching it. On the other hand, calendared vinyl is thicker and more forgiving when applied.
Mark explained that calendared vinyl often requires heat during installation to help mold it around curves or irregular surfaces. He also pointed out that when applying vinyl, you need to consider how freshly painted surfaces may affect the adhesive. In some cases, freshly painted surfaces may need to cure for a certain amount of time before applying vinyl. You don’t want your vinyl to stick or end up with bubbles!
The Verdict: Which Vinyl Is Better?
After our discussion, it was clear that there is no one-size-fits-all answer when choosing between cast and calendared vinyl. Each type has pros and cons; ultimately, the decision will depend on your specific project needs.
If you’re looking for long-term durability, superior conformability to complex surfaces, and a willingness to invest in proper installation techniques and maintenance, cast vinyl may be the better option for you. However, if cost-effectiveness and easy application are your top priorities or if you have a short-term project, calendared vinyl may be the way to go.
Ultimately, it’s important to do your research and consider all factors before choosing the right type of vinyl for your project. Proper care and maintenance are crucial for any type of vinyl to ensure its longevity and effectiveness.
Final Thoughts
So there you have it – our team’s insights on cast vs. calendared vinyl. We hope this discussion has helped shed some light on the topic and given you a clearer understanding of these two types of vinyl. Remember to keep these points in mind when making your next decision on which type of vinyl to use for your project, as choosing wisely from the outset can save you time, effort, and money in the long run.
Thanks for reading!
Keep an eye out for more informative discussions from Fusion Marketing, and if you need help with your vinyl projects for your home or business, don’t hesitate to reach out. We’d be happy to help!
