• Login Information
• Deals & Discontinued Items
• Finding Digital Media
• Case Quantity Discounts
• Quantity Discounts
• Aluminum Sheet
• Plastics Fabrication And Handling
• Technical Documents
• Application Icons
• Vinyl Films
  • Film Selection
  • Types of Film
  • Specialty Cast films
  • Calendered Film (Intermediate)
• Application Tapes

Login Information
Existing Customers
You can use your email address or login ID along with your password to log in to the website.

If you have an account with us but cannot remember your login but have an email address listed on the account, go here and use that email address to have your password sent to you.

If you currently have an account we ask that you do not create a new account online to obtain a login and Password, this can cause problems with Tax Exempt Information, Ship To, and any Terms Information that you may have listed on the original account, delaying the processing of your order. Just email us or give us a call- (800)-345-1712 Mon-Fri 7:00a.m.-6:00p.m (eastern time) with your account number and the login and password of your choice and we will set it up for you.

New Customers
Login and passwords are case sensitive and must be typed exactly how they were when they were created.

Please be sure to fill in your email address when creating the account in case you need to retrieve your password later.

Login and Passwords will work on your first order when the account is created but once the order submitted you will not be able to log back on to the website until that order is processed. Once you recieve an email confirmation on your first order your login information will be activated and will be able to log in at anytime.

If you create an account to place an order but never submit the order, no information will be sent so the account will not be created. An order must be submitted so the system can create the account.

If you experience problem while attempting to create an account please email us or give us a call (800)-345-1712 Mon-Fri 7:00a.m.-6:00p.m. (eastern time) for assistance.

If you created a new account and your business is tax exempt please fax your tax information to: (800)-868-9257 Attn: Fayth Dixon

Deals & Discontinued Items
Deals and Discontinued items are products that have been discontinued or have been special ordered and then canceled before delivery is made. Some of the items listed in the Deals & Discontinued portion of the web site may be able to be re-ordered or special ordered, depending on the product. However all items re-ordered/special ordered will be sold at current pricing, only items in stock at the time of purchase will be discounted. The items listed in this section are limited in quantity and may not be available at the time of purchase. If you have any questions regarding stock of a discounted item or wish to to see if a specific item can be re-ordered, and what the current pricing of the re-ordered item is, please give us a call at 800-345-1712

Choosing Digital Media

ICC Profiles: ICC (International Color Consortium) Profiles are simply look-up tables that describes the range of colors, or gamut, a printer can print. They define the most saturated colors available in a color space; i.e. the reddest red or deepest black your printer can produce. If you don't have a profile, The values that make up a color have no particular meaning — you can say something is red, but not exactly which shade of red. Having accurate profiles are the key to getting the correct color you need for a job. With accurate printer profiles, your prints will match more accurately to what you see on your monitor. Without profiles, it will take trial and error to produce the color you are looking for.

Case Quantity Discounts
Buy items such as Coroplast (Die-Cuts), Gatorfoam and Fomecor buy the case and receive a discount. When ordering by sheets the discount will be automatically be implemented at check out when count reaches full case quantity.
See Tech Document section on the product page for case quantities.

Quantity Discounts
Buy 5 or more of certain items and receive a discount. Call for more information on which items are included.

Technical Documents
Technical Documents such as MSDS sheets and other product information can be found on the lower left side of each product page. If there is product listed and the technical information you are looking for is not listed on the page, contact us with the product name and information that you are looking for and we will do our best to obtain the information and get it posted on our web site.

Application Icons
Application Icons can be found across the top right of each product page. These Icons are placed there to help you determine what Applications and Tools can be used for the product listed on that page. If you are unsure what an Icon means hold your mouse pointer on it for a second and it's definition will appear. Below is a chart that shows each Icon and its meaning.

Die Cut	FlatBed Digital	Indoor Use
Marine	Metal Tools	Outdoor Use
Paintable	Screen Printable	Wood Tools

Aluminum Sheet
Harbor stocks aluminum sheet stock in both mill finish and factory coated, finished panels. We stock panels up to 12ft in length.

Alloy-aluminum sheets from Harbor alloy code 3003, hardness code H14

Mill Finish sheets - These sheets are raw aluminum, straight out of the factory. Mill finish sheets are not coated in any way, and will usually have a light oil covering that comes from the machinery in the factory. Coated (Baked Enamel) Finish - These aluminum sheets are coated with a baked on enamel gloss paint finish. All panels are coated on both sides. Colored sheets are normally coated white on the back. All color panels are protective masked on the color side with a clear poly masking film.

Anodized finish - Anodizing is an electro-chemical coating process. This process is most often used to produce metal like finishes, i.e. gold, silver, etc. Anodized sheets are coated one side.

Bright and brushed - Bright refers to anodized panels with a mirror like finish. Brushed panels are physically brushed with a stiff roller brush to produce a lightly brushed (scratched) surface. Brushed panels help eliminate the fingerprint problem that you experience with bright finishes.

Colors - Harbor stocks over 40 colors, and routinely sells over 60 colors. If you require a sample, simply call Harbor for a full color chart, we'll be happy to send you one no charge. 800-345-1712

Thickness - panels are stocked in .032, .040, .063, .080, and .125. Additional sheet thickness are routinely available, just call Harbor.

Sheet Sizes - The panel sizes listed on this site are all UPS shipment sized. Harbor stocks panels up to 12 feet in length and 5 ft in width. Just call Harbor for size and shipping procedure answers.


Plastics Fabrication And Handling

ALWAYS TEST FABRICATION AND COATING PRIOR TO STARTING YOUR PROJECT

CIRCULAR SAWS
A circular saw blade with carbide teeth utilizing the "triple chip" tooth design is the preferred method of cutting plastic sheet. Table or overhead panel saws are normally used. Circular saws should be run in the speed range of 6000-8000 ft./min. Blades for cutting 3/32" and thicker material should have 3-5 teeth per inch. The hook or rake angle should be 10°- 15°. When sawing thin-guage plastic sheet, it is important to have a good supporting edge on the saw table with minimal gap between the saw blade and table supporting edge. Be sure table tops are smooth and free from projections that might scratch or mar plastic sheet.

Circular Saw Layout


Circular Saw Troubleshooting
PROBLEM: Melting or Gummed Edges

Suggested Solutions:
1. Increase blade tooth size
2. Reduce saw speed
3. Increase feed rate
4. Use air to cool blade
5. Use blade lubricant compatible with plastic sheet
6. Inspect blade for sharpness
7. Check blade-fence alignment
8. Reduce number of sheets in stack

PROBLEM: chipping

Suggested Solutions:
1. Decrease blade tooth size
2. Increase saw speed
3. Provide better clamping and/or support for sheet stock
4. Reduce feed rate
5. Check blade and arbor for wobble
6. Inspect blade for sharpness

BAND SAWS
Band saws are useful for trimming formed parts or irregular shapes. Band saws should be run at 2,500-3000 ft/min and have 8-12 teeth per inch. Coarser (larger tooth) blades perform better with thicker guage plastic sheet. Proper support of the part to be trimmed is important because vibration may induce cracking if the cut is not smooth.


BAND SAW TROUBLESHOOTING
PROBLEM: Melting or Gummed Edges

SUGGESTED SOLUTIONS:
1. Increase tooth size
2. Reduce saw speed
3. Use air to cool blade
4. Check blade sharpness

PROBLEM: Chipping

SUGGESTED SOLUTIONS:
1. Decrease tooth size
2. Slow down stock feed rate
3. Provide better clamping and/or support to eliminate vibration
4. Check blade sharpness

SHEARING
Plastic sheet may be sheared using a conventional sheet metal power shear. It is important to adjust the top blade clearance in relationship to the bed blade. A clearance of .001" is desirable to avoid a rough edge cut. Shear single sheets only.





ROUTING
Routing produces a smooth edge on plastic sheet and may also be used to cut courved or irregular shapes. Routers with a speed of 20,000 to 25,000 rpm are usually preferred. Use straight (fluted 2 or 3) carbide-tipped or high-speed steel router bits. Bits should be 1/4" to 1/2" diameter for best results. Use a router with at least 1 H.P. motor. Special care must be used when routing-use proper guarding and eye protection. Stock reed rates must be monitored closely. Feeding plastic sheet at excessive rates can cause vibration and cracking. It is important to feed the sheet against the rotation of the router bit and to provide a fence for sizing when making straight cuts.





DRILLING
Plastic sheet is easily drilled using ordinary high-speed steel drill bits. Regulate pressure and speed until a continuous spiraling chip is observed. Use air or water as a coolant if required. Using cutting oils may cause crazing. Be extremely careful if using taps or self-tapping screws, tapping creates notches that can result in stress cracks because many plastic sheets are notch-sensitive. Recommended drill speed is 350-1750 rpm.



The chart represents typical results

Hole Dia.	Drill Speed (RPM)
1/8"	1750
1/4"	1000-1500
1/2"	350-055

TRANSFER TAPE BONDING
Achieving a strong edge bond using solvents on thin-guage thermosplastics is extremely difficult due to the reduced size of the bond area. Structural bonding of thin guage plastics can be accomplished, however, by utilizing acrylic-based transfer tapes along with slight design modifications.

TRANSFER TAPE BONDING PROCEDURE

• Bend a small return on the appropriate part to be fastened approximately the width of the transfer tape.
• Clean tape contact areas with 50/50 isopropyl alcohol- water mixture.
• Apply transfer tape to the return.
• Remove masking tape and press the part into place.

HELPFUL HINTS

FOR TRANSFER TAPE BONDING
Rolling the bonded area with a small wood or rubber roller improves bond strength.

A nonstick slip sheet is useful for proper positioning of large or hard to handle parts.

Peel strength of long, lineal bonded areas can be increased with the addition of a mechanical fastener at both ends of the bond.

SCREEN PRINTING
Standard silk screening equipment with screens of varying mesh can provide excellent results. All thermoplastics sheets must be clean and free from surface residuals prior to screening. Many screeners use a pre-rinse of 50% isopropyl alcohol to clean surfaces of plastic sheet. Be sure to use soft nonabrasive cloths when cleaning to avoid scratching plastic sheet. Ionized air also provides a good method for removing lint and dust.

After screening, separate sheets on a drying rack until ink is completely dry. DO NOT pack sheets for shipment until inks are dry.

UV cure inks can be used with heavy guage plastic sheet but intense or prolonged UV may have a damaging effect on thin guages. It is not recommended for plastic sheet under .060 guage as some loss of physical properties occurs. Always test inks prior to use and always check with the manufacturer for use instructions.

Painting large surface areas with dark colors for outdoor exposure should be avoided. The dark color will change the rate at which heat is absorbed and can cause distortions.

PAINT AND INK REMOVAL
Use caution when removing over spray or drips. Be ure that the solvent wil not attack and craze poly carbonate. Isopropyl alcohol, VMandP naptha or similar solvents have been successfully used. Be sure to rinse with clear water after solvent application. Do not use scrapers, blades, nives, etc., as they will scratch plastic sheet. Always test a small area and observe possible attack before subjecting large sheet to solvent. Always test solvents prior to use and always check with the manufacturer for use instructions.

PAINTING
Many paints are available for plastic sheet. As with screen printing it is important to prepare the surface prior to painting by pre-cleaning. Use a mixture of 50% water and 50% isopropyl alcohol to remove surface masking residue. Be sure to dry thoroughly prior to painting. Use a soft non-abrasive cloth or sponge to avoid scratching plastic sheet. Conventional spray, spray masked, roller coat and brush are common application methods.

Painting large surface areas with dark colors for outdoor exposure should be avoided. The dark color will change the rate at which heat is absorbed and can cause distortions.

Avoid using paints containing toluene, xylene or solvents that will craze plastic sheet.

Be careful when using the paper masking for the design. Sharp knives can notch plastic sheet and allow crazing to occur. Be sure not to allow razor knives to penetrate the plastic sheet when cutting through masking paper.

A number of companies market paint systems for polycarbonate sheet and provide technical advice on application. Always test paints prior to use and always check with the manufacturer for use instructions.

MECHANICAL FASTENING
Aluminum rivets and machine screws may be used to join plastic sheet to other materials by utilizing proper attachment methods. Drilled holes should be a minimum of 1" from the edge, a distance of 2" would be ideal. Drill oversized holes and use fender type washers to distribute and cushion localized factors for dissimilar materials. Be sure drilled holes ar smooth and free from cracks. This method is for typical applications, always check with the manufacturer for exact specifications, and always test method prior to beginning your project.

This chart is for typical applications. Check with manufacturer for exact specifications

Sheet Size	24" X 24"	24" X 36"	36" X 48"	48" X 60"
Expansion Allowance	1/8" X 1/8"	1/8" X 3/16"	3/16" X 1/4"	1/4" X 5/16"
Edge Engagement	3/8"	1/2"	9/16"	3/4"
Rabbet depth	1/2"	11/16"	13/16"	1-1/16"

   

Comparative Expansion Rates

Material	IN./INºF
Glass	.0000050
Polycarbonate Sheet	.0000375
Aluminum	.0000129
Steel	.0000063
Acrylic	.0000410

GUAGE CONVERSION TABLE
This Chart is for typical applications please check with manufacturer for exact specifications.

MM	Fraction (inches)	Decimal (inches)
1	5/128	.040
1.5	1/16	.063
2	5/64	.080
3	1/8	.125
4	5/32	.160
5	3/16	.200
6	1/4	.250
8	5/16	.320
10	3/8	.375
12	1/2	.500
19	3/4	.750
24	1	1.00
30	1 3/16	1.200

Polycarbonate Or Plastic Sheet
Cleaning And Maintenance
Thoroughly rinse with warm water using a soft cloth or sponge. Wash with mild soap or detergent and rinse thoroughly. Dry material with a chamois or moist sponge. Do not use abrasive cleaners. Avoid cleaning in direct sunlight to prevent streaking.

Compatible Cleaners
The following cleaning agents are usually compatible with polycarbonate sheet products when used according to the manufacturers recommendations:

• Formula 409® (registered trademark of Clorox Company)
• Top Job® , Joy® (registered trademark of Proctor and Gamble)
• Palmolive Liquid® (registered trademark of Colgate Palmolive)
• Windex D with Ammonia D® (registered trade mark of Drackett Products Company)

Vinyl Films

• Film Selection
• Types of Film
• Specialty Cast films
• Calendered Film (Intermediate)

Film Selection
Selecting the best, most durable film for a specific application greatly depends on how and where it will be used. There are many variables to consider. We suggest you use these guidelines in conjunction with the product data sheets and technical information provided by the manufacturer. It is always advisable to make a test run of any product in order to determine its suitability for your intended use. Conduct your own tests, and formulate your own decision based on facts prior to initiating full production runs.

How does service life affect film selection?
Significantly. Film durability is determined by the manufacturing process (cast or calendared) and expected exposure to sunlight or environmental conditions.

Each film type has a different expected exterior durability. Generally, the adhesive and the film face stock do not disintegrate at the end of their expected life. The signs of aging include fading or darkening of colors, loss of the glossy finish, or lifting at the edges of the graphic.

For short-term applications, many specialty films are available. Calendared vinyl, which is often referred to as intermediate, is recommended for most medium-term applications. But for long-term applications, cast vinyl, also known as high performance, is recommended.

How does location affect film choice?
Will your graphics be used inside or outdoors? Sunbelt or Snow Belt? Stationary, or moving vehicle? Location determines film choice because of temperature, weather and ultraviolet (UV) ray exposure.

Outdoor locations exposed to the sun and weather are harder on graphics, and outdoor locations are not all created equal. For example: A sign located on the south side of a building in Arizona will take a greater beating from the sun than one under an overhand on the north side of a midwestern structure. Graphics on a moving vehicle, which constantly changes its position in relation to the sun, can withstand the effects of sunlight better than stationary graphics.

Temperature fluctuations also will cause film shrinkage. Calendared vinyl typically shrinks more than cast films because it is squeezed and stretched into shape as it is manufactured. When exposed to heat, it has a tendency to pull back into its original shape. Cast film, manufactured in a low-stress process, does not shrink as much.

For indoor applications, where sunlight is not a consideration, a variety of films are appropriate. For outdoor applications, calendared film is appropriate for short-term uses; cast film is ferred for long-term exterior signage. Do weather and pollution damage film?

Exposure to dirt, abrasion, pollution, solvents, fuels, and cleaning agents will impact graphic performance. Films constantly bombarded by air pollution may begin to deteriorate, leaving brown spots or cracks on the film surface. Exposure to solvents and other chemicals may break down the adhesive at the graphic's edges, causing wrinkling and shrinkage. Eventually, the graphic could curl and fall off.

In general, cast films will outperform calendared films under severe environmental conditions. Does mounting location affect material choice?

Yes. Pressure-sensitive films generally are not recommended for horizontal applications, such as on the hood of a vehicle. Such surfaces are exposed to extreme levels of heat and UV rays. Also, moisture and pollutants sit on these level surfaces, seriously impacting durability. To ensure acceptable film performance, pressure-sensitive graphics should be used in applications where the mounting angle is 450 or greater (angle measured up from a horizontal position).

Will the graphic be mounted high overhead or at eye level? Viewing distance of the sign will affect the size and complexity of your graphics. If your graphics will be viewed at close range, you may choose to use small lettering or detailed graphics. If the graphic will be easily accessible to pedestrians on a sidewalk or transportation platform, the possibility of vandalism should be considered. Over laminating the graphics or reverse mounting them on a clear substrate will prevent passersby from drawing on, or attempting to remove, the graphics from the substrate. What do I need to know about substrates?

The types of substrates on which a film can be applied depend on the type of film and the adhesive. Most films will adhere to a variety of metal and painted surfaces. When used properly, graphics films also can be applied to banners, flexible surfaces and some plastics. In addition, certain films are coated with special adhesives to handle tough applications. Translucent films, for example, may use adhesives designed to handle the difficult properties of substrates like scrim and LEXAN®

General Surface Preparation Guidelines:
To ensure that your graphics adhere properly, all substrates must be properly cleaned and dried before graphic application. If the surface is dirty, the film will adhere to the dirt instead of bonding with the substrate. In extreme cases, adhering vinyl to a contaminated substrate can cause the graphic to curl and fall off.

Visible dirt and grime can be removed by cleaning with a commercial detergent and water solution. Petrochemical contaminants must be removed with a commercial tar, wax, and grease remover. Many common brand cleaners will work, but first test them in an inconspicuous area of the substrate to verify that they will not harm the surface.

(TIP) After cleaning, use a clean cloth to thoroughly wipe down the surface with isopropyl alcohol or a solvent cleaning fluid to remove cleaner residues. Dry the surface with a clean cloth prior to the fluid evaporating.

Painted Surfaces:
Vinyl films typically adhere well to a wide variety of paints, form common latex and oil base paints to acrylic enamels and lacquers.

All priming, painting and retouching of surfaces should be performed according to the paint manufacturer's instructions. If vinyl graphics are applied to an improperly painted surface, the paint may be pulled off when the vinyl is removed.

(TIP) Paint can be checked for adhesion to the substrate by applying a piece of masking tape, rubbing it down firmly, and snapping it away from the surface. If any paint is pulled up by the masking tape, do not proceed with the application. If the surface has just been primed or painted, make sure it is thoroughly dry before applying your graphic. Some solvent-based paints or primers can be touch-dry within a few hours, but solvent evaporation may still take place for several days. Be sure to follow the manufacturer's recommended drying and curing procedures or out gassing may occur. Applied too soon, the graphic can trap solvents between the surface and the graphic, causing the film to bubble and softening the adhesive. The result can be vinyl distortion, and, in severe cases, graphic failure. Even freshly painted surfaces should be wiped down with isopropyl alcohol prior to application to remove additives that may have migrated to the surface as the paint dried. Such additives can inhibit film adhesion. Banners:
Vinyl films are most often used with polyethylene and vinyl banners. Vinyl may also be used on other banner materials such as polyesters, nylons, and others. It is best to apply vinyl graphics to the banner's smooth side. Most banner substrates are highly plasticized. With time, the plasticizers will migrate to the banner surface and soften the adhesive graphics. The result is bubbling or tunneling of the film. In extreme cases, the vinyl graphics may fall off the banner.

(TIP) To ensure satisfactory graphic performance, wipe the banners down with isopropyl alcohol prior to application. After applying the graphic, leave the banners unrolled for at least six hours. Always roll banners with the graphic's side out. For new banner materials, make a trial application. Your best bet is to check with the banner manufacturer to determine which materials are recommended for use with your vinyl graphics. Plastics:
Injection or blow-molded plastic surfaces usually have a silicone residue on the surface. This is a mold release agent from the manufacturing process, and may prevent your vinyl graphics from adhering properly. For proper adhesion, the plastic must be heat-treated to burn off the silicone.

Irregular surfaces:
Uneven surfaces may dictate film choices. If a nonconforming film is used over surfaces such as overlap seams or corrugations, the film may lift away from the substrate. Cast vinyls conform best to abrupt surface contours. For such surfaces, cast films are the appropriate choice even for a short service life.

Are many colors available? Can custom colors be ordered?
Does your customer want a standard color? Or is it necessary to match a specific corporate logo color? While the calendared films color choices have expanded to include some specialty colors, your broadest color palette is available in cast films. If a special color is requested, custom color matching is an option for cast films.

What if my customer wants the graphic visible at night?
Reflective materials will help keep your graphics working long after the sun goes down. These films are particularly good for safety applications. For backlit awnings or sign faces, translucent cast films work best.

My customer's graphics may change periodically. Can I remove vinyl markings?
If the graphics on your customer's delivery van need to be changed periodically, you may need to consider the removability of your vinyl graphics. In some cases, films with removable adhesives may be available from your vinyl manufacturer. These films provide a strong bond with the substrate surface, but they are designed to be easily removed.

Since many films are not readily available in removable constructions, you will normally need to use heat or chemicals to remove vinyl films. Differences in film characteristics and substrate surfaces will combine to make each removal slightly different. Always test a small area before beginning removal to ensure that the substrate will not be damaged.

(TIP) The heat removal method uses liberal amounts of heat to loosen the adhesive bond. Beginning at the corner, pull the graphic slowly from the substrate at less than a 90-degree angle while continuously applying heat to the vinyl. The chemical method involves spraying the graphic with a chemical removal agent. After 10 to 15 minutes, the vinyl will begin to bubble and can be peeled from the surface. A hot water pressure washer can be used to assist with removal of stubborn graphics. Always test the substrate to insure that you will not damage the surface itself.

How does the way I prepare my vinyl markings affect my film selection?
Many of your graphics will probably be produced using standard computer cutting methods. Here, typical graphics film constructions are appropriate. For digital printing, screen-printing, films backed with a heavier liner might be necessary. Although most graphics films use a 78# liner, film constructions with heavier liners are available. The benefit: a heavier liner provides improved lay flat, stiffness, and smoothness required for printing applications.

Want to add some extra color to vinyl graphics? You can, by airbrushing or painting the film face. Special effects you can achieve include graduated colors, horizon lines and multicolored cloud effects. Both cast and calendared films should be tested for paint adhesion prior to use.

How do application conditions affect film adhesion?
Self-adhesive films work best when they are thoroughly rubbed down onto a clean, dry surface in normal working temperatures. The application temperature range of most vinyl films runs from a low of 40 F a high of 90 F. If the temperature is too low, the film adhesive may approach a solid, frozen state. This will prevent the adhesive from flowing and adhering to the surface. If the temperature is too high, the adhesive may grip onto the substrate immediately, preventing any repositioning. In addition, the vinyl film will become so soft that it will warp and stretch easily.

Carefully note that the application temperature refers to the temperature of the substrate and the vinyl, not the air temperature.

(TIP) You can control your application conditions to a certain extent. On a cold day, vehicles can be moved into the sun. On a hot day, the application can be performed in the cooler morning hours or in the shade. Surfaces also can be sprayed with water to cool them.

How do I store graphics prior to application?
While most vinyl graphics are applied to the substrate shortly after they are cut, there may be occasions when you need to store cut graphics. Generally, graphics can be stored on the original liner as long as they are cut with the proper amount of weight. Be sure to weed the graphics and apply premask before the vinyl is stored.

The amount of weight or pressure you should use will depend on the film type, blade type and sharpness, vinyl cutting equipment, cutting speed and other factors. The lightest weight tht will cut through the face stock and adhesive is the best choice. Too much weight or pressure may score the liner and facture the silicone release coating. If the release coating is fractured, uncoated paper will be exposed to the adhesive. If the adhesive bonds with the exposed paper, it may be difficult to remove the matrix and the graphic form the liner.

Applying premask to the weeded graphic before storage will minimize problems in removing the graphic from the liner. During storage, the premask has time to build a stronger adhesive bond to the graphic, which can help give the premask the strength to remove even stubborn graphics from the liner.

It is best to sore uncut films in their original packaging and away from direct sunlight.


Types of Film
The typical pressure-sensitive film construction consists of facestock, an adhesive, and a liner. Most of the materials used for computer cut graphics use similar adhesive, and liner components.

Graphics films typically use permanent acrylic adhesives. These adhesives offer good heat and chemical resistance, excellent UV stability, and good adhesion to a variety of substrates. Adhesives can be coated using either emulsion or solvent systems. The key difference is that emulsion systems use water as a carrier. In either system, the carrier fluid is burned off during the coating process, leaving the adhesive compounds behind. The field performance of the adhesives is generally the same regardless of the coating system used.

The typical liner material is a 78# paper liner. 90# paper liners are also used in applications where lay flat characteristics are important. Liner materials are coated with a thin layer of silicone. This coating keeps the adhesive from permanently sticking to the liner paper. If the release coating is fractured by heavy cutting, paper fibers will be exposed. Adhesive bonding to the exposed fibers may make graphics difficult to remove.

Most graphics materials use a vinyl or polyester film for the facestock. Differences between the types of film give the materials their unique looks and properties. These differences are explained in the following sections.

Cast Films (High Performance)
Vinyl films are a combination of polyvinyl chloride (PVC) resin, plasticizers to soften the vinyl for flexibility, stabilizers to protect against heat and UV deterioration, color pigments, and modifiers to adjust performance characteristics. The grade and quality of film produced depend on these ingredients and the manufacturing process. Cast film is produced by pouring (casting) liquid vinyl onto a very smooth sheet. As the material moves through heat curing ovens, the solvents are removed to fuse the remaining solids into a film. Once the film emerges from the ovens, it is ready for adhesive coating.

Characteristics and Performance
Cast film, often referred to as high performance, is normally warranted for an outdoor durability of five to eight years. Cast film colors are more resistant to fading that calendared film colors because cast films contain more pigments and UV stabilizers. Additionally, cast vinyl is dimensionally stable and resists shrinkage. This stability is the result of its low-stress manufacturing process. Pouring the vinyl onto a sheet leaves the film with little tendency to shrink back. Cast vinyls are available in a wide range of standard colors. And custom color matching makes the color palette practically limitless. While minimum manufacturing runs are required for custom colors, color matching can be a viable option for large jobs.

Colors are more opaque in cast film than in calendared film because of the proportionally higher pigment content. The high-gloss finish of cast film is created by the smooth casting sheet onto which the liquid vinyl is poured. Other surface finishes can be created by using different paper types in the casting process. Textured paper, for example, is used to create a matte finish.

With its thin two-mil face, and its higher levels of plasticizers, cast film is one of the most conformable graphics materials. As such, cast film is recommended for use on textured or irregular surfaces and abrupt surface contours such as rivets and corrugations.

The key issue in applying cast film to textured surfaces is conformability, not adhesion. Textured surfaces actually have more surface area available for the adhesive to stick to than a flat surface. But the surface irregularity makes it more difficult for the adhesive to make contact.

(TIP) Apply a little heat to the film to soften it and increase its ability to conform to the surface texture. Then apply to the surface using a surface conforming squeegee, rivet brush, or cut-off paintbrush.

Most cast films can be used to cut text as small as ¼ inch. Use a 300 blade for cutting. Cutting weight requirements generally will be less than with other films. The exact amount of weight to use will depend upon film type, blade type and sharpness, vinyl cutting equipment, cutting speed, and other factors. To determine the correct cutting weight for a film, make a test cut prior to cutting the desired legend.

Special Considerations and Uses
Mottling is a special consideration for cast films. Mottle looks like a haze, or blotchy dull spots on the vinyl film surface. This condition occurs when the glossy top surface of soft, conformable vinyl film is pressed against the release liner in a wound roll. While conformability is a benefit of cast vinyl films, it also makes them prone to mottling. Factors affecting the level and severity of mottle include heat, time wound in a roll, roll tightness, film formulation, and liner type. Also, film color and gloss level have an effect. Mottle will show up more on higher gloss films and darker colors.

(TIP) To prevent mottle, store cast films in a cool area, away from direct sunlight or a heat source. Rolls should be wound as loosely as possible and suspended or kept in boxes with end plugs. Laying rolls on their sides can produce a "band" of mottle.

(TIP) Mottle can be reversed. To eliminate mottle, unroll the vinyl and leave it lying in a warm area. Or, carefully use a heat gun (or hand-held hair dryer) over the film surface. The mottle should begin to disappear. Once film is applied to a substrate, most mottle will eventually disappear with time and exposure to heat or sunlight.

Some cast facestocks are also used in pressure=sensitive constructions that are approved for use in the automotive industry. To qualify for automotive approval, a film must meet an extremely detailed set of specifications and test requirements. Cast film has the superior performance characteristics necessary to meet these requirements.

Cast films are one of the most versatile graphics products. They can adhere to a wide range of substrates and surface contours. Generally, they offer the best performance features under tough environmental conditions. Cast materials are preferred for long-term exterior identification signs, as well as decorative or commercial graphics on cars, trucks, and boats.

Specialty Cast films
To create splashy graphic effects, cast films are available in specialty formulations = metalllics, translucents, and fluorescents. These films have3 many of the same characteristics as standard cast films, but durability may vary greatly.

Metallic Cast Film
Tiny metal flakes are imbedded in the vinyl compound to produce the glittering look of metallic cast film.

Characteristics and Performance
Outdoor weather performance is not as good as opaque cast films. Metallic flakes exposed on the surface of the film provide ready sites for degradation to begin. When the film ages, tiny brown spots appear on the film face. This is the result of oxidation (rusting) of the metal flakes.

Performance characteristics are similar to opaque cast films. However, elongation *stretchiness) is not as good. As a result, metallic cast films have the potential to break more easily during weeding.

Special Considerations and uses
Metallic films can be used to create elegant decorative effects and accents on everything from vehicles to exterior lettering to general graphics.

Translucent Cast Film
Special translucent pigments in the film allow light to pass through when backlit. Colors are rich and uniform under both transmitted and reflected light. Translucent graphics on an awning, for example, will maintain the same bright colors when lit from the front during daylight hours, and when backlit during evening hours.

Characteristics and Performance
Exterior durability is typically five to seven years. Translucent film is a two-mil cast vinyl available in a variety of standard colors. Custom color matching is relatively easy.

Conformability to substrate surface contours is good, as are its cutting and seeding characteristics. Application can be in sheets as background colors or computer cut to form legends or graphic images.

Special Considerations and Uses
(TIP) In backlit applications, the internal lamps may show up as streaks, hot spots or bright outlines on the face. To reduce this effect, use a diffusing film on the back. Other options are to use deeper cabinets or multiple film layers.

Some substrates commonly used for backlit applications can present challenging application conditions. Some polycarbonate materials absorb moisture and will outgas. Be sure to remove moisture before vinyl film is applied. If not removed, it will rise to the substrate surface over time and be trapped beneath the film, leaving permanent bubbles. The potential for bubbling increases with the number of film layers used. To avoid this problem, bake polycarbonates prior to pressure-sensitive film applications. Check with the substrate manufacturer for specific baking procedures.

Awning materials also are difficult substrates. The problem here is plasticizer migration, which can affect the adhesive of the translucent film. Bubbling, tunneling, or graphic failure may result. To minimize these problems, only use translucent films on scrim sealed with an acrylic coating. Use the wet application method when applying translucent to scrim. Make sure the graphics are completely dry before installation on a building. Until thoroughly dry, the adhesive bond has not developed completely, and the graphics could slide around on the substrate.

Translucents often are used for graphics on flexible and rigid backlit awnings and illuminated sign faces. Examples include gas station canopies, illuminated restaurant signs, and illuminated awnings in strip malls. These films also work well for backlit menu boards, point-of-purchase graphics, and windows. Translucents can be used to achieve a variety of unique effects by overlaying films to create new colors, or to achieve different colors during the day or night.

Fluorescent Cast Film
Bright, vibrant colors are available in fluorescent film. Fluorescent pigments make the film appear as though it radiates light.

Characteristics and Performance
Exterior durability of most fluorescent films is short-term, typically about six months and up to two years. Otherwise their characteristics are similar to other cast films.

Fluorescents are intended for use on flat surfaces. These films do not work well on irregular surfaces. The heat required to conform the film to the substrate discolors the film.

Special Considerations and Uses
Because fluorescent pigments are very susceptible to fading when exposed to the sun's ultraviolet rays, exterior durability is the major limiting factor. Since all fluorescent films use similar pigments, the differences in durability are due to other elements of the films' constructions. To extend beyond a six-month exterior durability, some films use a UV-resistant top coating. Other films are formulated to fade to non-fluorescent shades of their original colors instead of fading to white.

Fluorescent pigments are very transparent. To help bring out the color, a white adhesive or an extra layer of white film is used underneath the face stock. Because fluorescent films require an underlying layer of white, they cannot be reverse cut for mounting on a clear substrate.

Fluorescents should only be used for short=term signage. They are ideal for high=visibility applications, such as promotional and safety signage. And their bright neon colors make them ideal for splashy racecar graphics, as long as the wear and tear of competition ensures that the short exterior life of the film is not a concern.


Calendered Film (Intermediate)
Calendered film often referred to as intermediate grade is manufactured through a calendaring process. In simple terms, a molten mass of vinyl is pulled through pairs of polished heated rollers until it is stretched to a thickness of 3 to 4 mils. The film is then wound into rolls for adhesive coating.

Historically, calenderer films have been less durable and less glossy than cast films. As such, they were sold as intermediate or economy grade films. Because of changes in film composition, tow types of Calendered film are now available _ polymeric and monomeric compositions. Although calendered films cannot completely match the performance of cast film, the increasing use of polymeric compositions has dramatically improved the characteristics and performance of calendered vinyl. Calendered films may be a less expensive film option because the calendaring process lends itself to long, efficient runs.

Characteristics and performance
Exterior durability of calendered film is generally less than that of cast films. Calendered film colors fade more quickly than those of cast film because calendered film contains fewer pigments and UV stabilizers. Also, calendered film is less dimensionally stable than cast film because of its manufacturing process. Calendering forcibly stretches and squeezes the vinyl material into shape. As a result, the material has a tendency to shrink back to its original form, particularly in the web direction (i.e., along the length of the film). In exterior applications where calendered film is subjected to wide temperature fluctuations, shrinkage is a major consideration.

Custom colors generally require high purchase minimums. Small calendered film runs are impractical due to the scale of the manufacturing equipment and the large amount of material required for startup.

Although nearly twice as thick as cast film, calendered film is not correspondingly opaque. This lower opacity is another result of the lower pigment content.

However, calendered film's 3 to 4 mil thickness increases resistance to abrasion and provides greater tensile strength. This makes the film less susceptible to scratching or gouging, and less likely to tear. But again, due to its thickness and shrinkage tendencies, calendered film does not conform well to irregular application surfaces. As such, calendered film is typically recommended for application on flat surfaces or simple curves. Generally, it is not appropriate for use over rivets, corrugations, complex curves or irregular surfaces.

Cutting and weeding characteristics vary depending on the film type. The minimum character height for text cut from calendered film is typically ½ inch. Use a 300 blade for cutting. Generally more cutting weight is required than with cast films. The amount of weight to use will depend upon the film type, blade type and sharpness, vinyl cutting equipment, cutting sped, and other factors.

Special Considerations and Uses.
Calendered films traditionally have contained monomeric plasticizers. Simply put, the plasticizer molecules are smaller and more mobile. As a result, plasticizers in the film are unstable, leading to migration of these elements into the adhesive. In other words, the plasticizers tend to shift to the outer film surfaces, which brings them in contact with the adhesive. This weakens the adhesive bonds and also contributes to shrinkage. In addition, this shifting of major components within the film weakens the material, making it more susceptible to cracking and color fading. For this reason, momomeric calendered films typically are limited to two to three year exterior durability.

The performance characteristics of polymeric and monomeric composition calendered films are different. Polymeric and hybrid polymeric calendered vinyls can actually approach cast film performance levels. These calendered films are superior in colorfastness, shrinkage resistance, gloss, and outdoor durability. These films contain polymeric plasticizers which are larger, more permanent molecules. The resulting increase in the stability of the molecules means there is less migration to affect the strength of the adhesive and the film. Since plasticizers provide flexibility, their stability within the film also translates to a material that stays flexible longer.

Calendered film is an excellent choice for many signage applications, although it's important to keep performance requirements in mind. It is most appropriate for sign applications with flat surfaces that are not subject to long-term UV exposure, temperature extremes, or petrochemicals.

Calendered film is most often used for short-term banners and temporary signage. It is also appropriate for indoor signage. It is an economical choice for promotional signs; show cards, point-of-purchase displays, and window graphics.

Reflective Film
Reflective films are specially designed for 24-hour visibility applications. The reflective characteristics are created by tiny glass beads incorporated into the film surface, which bend incoming light and reflect it back toward its source.

Characteristics and Performance
Many different reflectivity levels and film constructions are available, and film performance characteristics will vary depending on the construction. Exterior durability ranges from two to seven years. Face film thickness can range form 3.5 to 6.5 mils. Reflectives typically resist shrinkage.

While color selection generally is limited, custom color matching is relatively easy. Reflectives are completely opaque and feature a high gloss surface.

Conformability characteristics are good, with certain types of reflective film being appropriate for use over rivets and corrugations.

Use a 450 blade for cutting. Although a 300 blade may work, the more pointed tip of the 450 blade is more effective for cutting thick films such as reflective. Also, more cutting weight is required than with other films. When cutting reflectives, the glass beads in the film will cause blades to wear out more quickly. Minimum character height for legends is typically ½ inch. Reflective signs are normally read from a distance, so text needs to be at least this size for both readability and light reflection.

Special Considerations and Uses
Reflective films may use either a vinyl or a urethane facestock. Urethane films usually offer good durability and increased abrasion and graffiti resistance. However, they are also more brittle and less conformable than vinyl films. Reflectives are also available in varying reflectivity levels. Two types commonly used in computer cut signage are Utility (or promotional) Grade and Engineer Grade. Both classifications refer to the level of the film's reflectivity. Utility Grade reflectives have lower reflectivity and typically are formulated for a shorter exterior durability. In addition to offering a higher reflectivity, Engineer Grade films typically feature a longer exterior durability, increased conformability, and better cutting and weeding characteristics.

Reflective films are ideal for day and night high-visibility applications. Engineer Grade reflectives are recommended for longer-term applications _ highway signage, truck markings, and decorative striping. Utility grade films are frequently used for short-term applications such as identification signage on emergency vehicles. These films are also appropriate for reflective backgrounds for signs.

Specialty Films

Metallizied Polyester
Metallized polyesters are available in bright silver and gold finishes as well as brushed or matte chrome. Polyesters are one to two mil films that are coated with a thing layer of metal. Exterior durability generally ranges from one to two years, but some polyesters are not recommended for exterior use. Polyesters are primarily used on flat substrates, because they are less flexible materials. Also, if you plan to use a gold film on a clear substrate like glass, be careful in your film selection. Double-sided gold films are readily available, but some gold films have a silver finish on the adhesive side. Metallized polyesters are ideal for creating elegant lettering and graphics, and are frequently used for decorative trim, nameplates, promotional signage, and window graphics.

Gold Leaf Films
Gold leaf is an especially attractive film for creating sophisticated and elegant graphics. It is an alternative to gold leave gilding by hand. Some films use real gold, laminated with clear cast film, to produce a material, which can be computer cut. Other films offer a simulated gold leave look. Exterior durability ranges from five to fourteen years. Although some gold leave films are single-sided, double-sided films are available for reverse cut applications. Applications include signage in banks and professional buildings, fire trucks, yacht transoms, and other upscale applications. Double-sided gold leave can be used for decorative graphics on mirrors, windows and glass doors. **Avery Dennison Marking Films Division prepared portions of this guide, and the guide is intended as a reference for proper selection of graphics films division. **

Avery Dennison WorldWide Graphics

WHAT ARE APPLICATION TAPES?
TAPES FOR Sign making, SURFACE PROTECTION, AND VINYL CONVERTING

Paper Application Tapes
R Tape' offers a comprehensive range of specialized paper application tapes to satisfy every sign making application.

Standard paper application tapes provide dependable performance at economical prices. They feature white translucent standard weight saturated paper with medium tack adhesive for medium to large size lettering and graphics, or high tack adhesive for small to medium size lettering and thermal die cut graphics.

Premium paper application tapes resist moisture and offer greater conformability to irregular surfaces. These tapes feature white translucent heavyweight saturated paper with medium or high tack adhesives for medium to large size lettering, graphics and thermal die cuts; and ultra high tack adhesive for small lettering, graphics, and other hardtolift vinyls.

Premium tapes featuring clothlike heavyweight saturated paper with excellent "lay flat," superior conformability and easy unwind are also available in a wide range of adhesive levels.

For surface protection, R Tape offers a standard weight saturated paper tape with low tack adhesive, and premium weight saturated paper tapes with low and very low tack adhesives.

CLEAR APPLICATION TAPES
Compared with paper tapes, clear application tapes allow more precise registration, especially with light and multicolored vinyls. They are ideal for wet method applications and humid environments, and can remain applied to graphics during extended storage.

R Tape offers many clear application tapes having medium to high tack adhesive levels. One features a transparent, heavy gauge, embossed, nonglare film that is easy to snap and tear, and performs much like paper, the other is a crystal clear film that allows the most precise registration possible. Also offered is a clear film featuring an adhesive system that adheres only to vinyl for transferring lettering and graphics to poster board, foam board, and other fragile substrates.

TAPES AND FILMS FOR SCREEN PRINTED DECALS, TEXTILE SCREEN PRINTING EQUIPMENT, AND OVERLAMINATION

Paper Tapes for Decal Protection and Application
R Tape manufactures a wide range of specialized, selfwound paper tapes to protect and apply screen printed vinyl graphics of any size to any wet, dry, flat, or irregular surface.

TAPES AND FILMS FOR SCREEN PRINTED DECALS, TEXTILE SCREEN PRINTING EQUIPMENT, AND OVERLAMINATION CONTINUED...
Standard paper tapes are offered in low tack levels for protecting and/or premasking large vinyl graphics, in medium tack levels for medium to small size graphics, and in high tack levels for small vinyl graphics and prespaced lettering. All provide dependable performance at the most economical prices.

Premium paper tapes feature white translucent heavyweight saturated papers for Superior conformability over irregular surfaces and greater resistance to moisture. Premium tapes are offered in "medium" tack levels for large and medium size premask applications, to "high" tack levels for small size premask and computer cut or thermal die cut graphics. Recently developed products include premium premasks with adhesive systems specially developed to lift and release fourcolor decals printed with UV inks which have greater surface irregularities than solvent based inks.

TAPES FOR SCREEN PRINTING FRAMES AND PALLETS
To prevent ink from creeping between the frame and screen, R Tape offers "block out" tapes that are applied along the inside perimeter and underside of the screen, forming an adhesive bond which resists attack by inks and cleaning solvents. The tapes can be removed in one pull, with no adhesive residue.

In addition to standard "Blue Block Out" tape for wood screen frames, "Zone Coat" and "Split Liner" tapes for metal, roller, and retensionable frames are offered to allow movement between the screen and frame. For protecting textile screen printing pallets, R Tape offers heatresistant tapes with slightly creped or smooth finishes. Multi layering of tapes on the pallet allows quick peeloff of top layer with no downtime.

OVERLAMINATING FILMS FOR ROLL LABELS AND DIGITAL IMAGING OUTPUT
Crystal clear high gloss polypropylene films in self wound and release liner formats are available in a wide range of standard thicknesses and adhesive coating weights. These pressure sensitive film products are FDA approved, laser printable, UV resistant, nonyellowing, and provide exceptional protection even in such demanding applications as battery labels and heavy duty edge reinforcement.

Matte finish polypropylene films are available for labels printed with bar codes and for graphics where low glare is a requirement.

High gloss, opticallyclear polyester films are recommended for exterior use labels and digital imaging output requiring maximum resistance to moisture, abrasion, weathering and UV light.