Cast Vinyl

Choosing a vinyl film comes down to a few factors, application and price point being chief among them. Cast vinyl is one of the newer films and provides more long-lasting use than other choices, which makes it a wise investment for applications that face wear and tear or need to look pristine long term. 

What is Cast Vinyl?

Cast vinyl is a type of self-adhesive vinyl wrap that is on the high end of the spectrum. It is able to be heated and stretched into a deep recess or curve without issue. The manufacturing process begins with the cast vinyl as a liquid, somewhat like paint but thick like plastic. It is then blended with PVC, pigments, and plasticizers by a machine into a more consistent mixture at specific speeds for a specific amount of time. The mix, called organosol, is casted and squeezed into a casting sheet which determines the final texture of the cast vinyl.

After being laid into a casting sheet, the mixture is sent through several ovens to evaporate the existing solvents, which leaves behind a solid film. The film is then rolled onto a large-diameter core to add an adhesive coating made, altogether adding up to being between 1 and 2 millimeters thick. 

Benefits of Cast Vinyl

As mentioned earlier, cast vinyl is considered an industry premium and has several properties that make it a top choice for a wide range of applications:

  • Flexible
  • High-quality
  • Long-lasting
  • Soft
  • Thin

Due to these properties, it is a high-quality solution for outdoor use as it can withstand extended exposure to the elements and temperature fluctuations. Other advantages of using cast vinyl film include:

  • High-durability
  • Minimal shrinkage
  • Thinner gauges, making them a perfect solution for grooves and curves
  • Maintains color and its properties better than other vinyl film choices
  • Adapts well to a wide variety of surfaces and shapes
  • Has a paint-like appearance finish

Many of the benefits of cast vinyl films are due to the plasticizers and raw materials used in their production being of much better quality than other types. The thinness of the film gives it the ability to conform to ridges and intricate curves while also being able to change as needed. 

Applications for Cast Vinyl Films 

Cast vinyl is one of the thinner forms of film and the process helps it remain relaxed, making it a comfortable, durable, and flexible vinyl that holds its color. These features make it an ideal type of cast film for complex surfaces and applications that require a smooth finish, vehicle wraps being a top example. Cast vinyl is manufactured in small batches, which translates to a wider variety of colors and finishes for the person or company buying it. Due to the array of colors, finishes, and the film's ability to cover complex surfaces that require seamless finishes, it is a top selection for various applications, including:

  • Architectural purposes
  • Plotter cut vinyl lettering for banners
  • Promotional signs
  • Small die-cut decals, including window decals and bumper stickers
  • Vehicle numbers and letters
  • Vehicles, including boats and RVs

Cast Vinyl & Vinyl Wrap Resources

To learn more about cast vinyl film and how it delivers quality solutions to an array of applications, we encourage you to explore the articles below and discover how it can enhance a wide range of products and items.

Why Cast Vinyl is the Best Choice for Vehicle Wraps

Vehicle wraps have become an increasingly popular way to promote brands, create a uniform and professional appearance, and personalize cars, trucks, boats, RVs, and vans. However, not all vehicle wraps are created equal, with some fitting other applications better than others. 

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Cast Vinyl: The Best Choice for Harsh Weather Conditions

Outdoor signs are an essential element of any business's marketing strategy. They help to attract new customers, build brand recognition, and provide critical information about services, deals, and that you exist. 

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How Cast Vinyl Helps Sign and Banner Graphics Stand Out

When it comes to creating impactful signs and graphics, the type of material used can make all the difference. Choosing a subpar film can dull the impact of the graphic or sign, leading to additional costs due to damage or replacement.

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Image of a vinyl on the side of a wall in a office building.

Step-by-Step Guide to Applying Cast Vinyl

Vinyl applications offer a versatile and visually appealing way to enhance surfaces, whether for signage, wall graphics, or vehicle wraps. To ensure your project reaps the benefits that cast vinyl delivers proper application is essential. Below, we provide step-by-step instructions to guide you through applying cast vinyl correctly to avoid common issues.

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View of a vinyl on the side of a grocery store outside.

Troubleshooting Common Cast Vinyl Issues

As with any other material, cast vinyl can develop issues and problems for a few reasons. Sometimes they occur due to application error or because the vinyl wasn't made well, but no matter the reason, it needs to be addressed. Below you'll find the most common problems that occur with cast vinyl and how to troubleshoot a solution so your application doesn't become costly or need a replacement so soon.

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Image of a vinyl inside an office building.

UV Protection: Preventing Fading and Degradation

In the competitive world of business, first impressions matter. Imagine investing time and resources into creating eye-catching banners, signs, and vehicle graphics, only to see them fade away under the relentless assault of the sun's UV rays. UV degradation can silently erode your visual impact, costing your business both money and reputation. In this article, we will delve into the importance of UV protection for your media and why cast vinyl emerges as a reliable solution.

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Image of a rough rap on the side of a building.

Cast Vinyl vs. Heat Transfer Vinyl

Selecting the right vinyl for your applications means choosing between a few different options, one common struggle is choosing between cast vinyl and heat transfer vinyl (HTV). It is a critical decision for suppliers and businesses alike due to each option coming with its own set of advantages and drawbacks.

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Image of a rough wrap on the side of a building.

Cast Vinyl vs Calendared Vinyl: Differences and Applications

When a business knows it needs vinyl graphics, it can be difficult to settle on which type of material; cast vinyl vs. calendared vinyl is a decision that can significantly shape the outcome of projects, impacting everything from durability to precision. To help settle on which type of vinyl is best for a particular application, read below and review the manufacturing processes, common applications, and key distinctions between these two vinyl options and become equipped to make informed choices tailored to a project's unique needs.

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View of a owl vinyl on the side of building windows.

Cast Vinyl for Labels and Packaging

The choice of material is essential for branding and packaging, not only to ensure quality protection of the merchandise packaged but to allow for a greater visual impact. Cast vinyl is commonly used as a packaging and label material, considered an excellent solution that delivers on the most important areas: customization, protection, and aesthetics. 

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Cast Vinyl for Outdoor Advertising

Outdoor advertising can be difficult; facing the elements, foot traffic, and wear and tear can not only impede the impact of your advertising but also cost dollars with repairs and replacements. Selecting the right materials is critical to the success of your campaigns, and out of the many options availa

Assessing Cast Vinyl Durability Requirements

Selecting the right vinyl material is essential to a lasting and high-quality finish and for protecting the substrate itself. Cast vinyl, known for its unique characteristics, is the popular choice for numerous applications, though many types of applications have their own demands and requirements needed for cast vinyl to effectively protect. How can a person evaluate the durability requirements for the various applications cast vinyl is popularly used for?

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Cast Vinyl Scratch and Abrasion Resistance

In the competitive world of business, aesthetics matter. For businesses seeking a durable solution that combines both style and resilience, cast vinyl films with exceptional scratch and abrasion resistance stand out as a top choice. In this article, we delve into the importance of cast vinyl films, exploring their abrasion-resistant features and the key considerations for businesses looking to enhance the longevity and visual appeal of their products.

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Cast Vinyl Expected Lifespan

Vinyl film is used for an array of applications, from cast to calendered, but when longevity is a concern, which type of vinyl do you use? Cast vinyl delivers enormous benefits to substrates, from car wraps to wall graphics and signage to banners, but what good is paying for a material that doesn't last long enough?

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Tips for Successful Cast Vinyl Installation

Cast vinyl graphics and wraps offer a fantastic way to transform surfaces, be it vehicles, signs, or other applications when installed properly. Improper cast vinyl installation, on the other hand, can cause many issues, not just with the application but also with the vinyl itself. If pursuing installation yourself, it's critical you understand how to do it correctly or hire a professional to do it for you.

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Cleaning and Maintaining Cast Vinyl Graphics

Vinyl graphics, especially vehicle wraps and signage, play a crucial role in business branding. Proper care and maintenance are essential to maintaining their quality over a long period of time, though many don't know proper cleaning practices for cast vinyl. It's critical to use the proper tools, techniques, and solutions to preserve the graphics instead of damaging them accidentally.

Below we detail proper cl...

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Proper Handling and Storage of Cast Vinyl Rolls

Storing and working with cast vinyl film means risking damaging it before it can be applied or worked with. Few things are more frustrating than ruining stock before you have the chance to use it or sell it. While cast vinyl rolls are highly durable and used to enhance graphics, among other types of applications, their longevity and quality are at risk when not stored or handled properly.

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