Decal 101

SCREEN PRINTING - This is the method of forcing a heavy coating of ink through a fine mesh onto the decal or sign substrate. The result? A longer lasting decal that withstands weather, chemicals and fading from sunlight. This method was originally created to meet the demanding specs of military and civilian aircraft, trucks and outdoor signage. Communication Graphics lays down an ink density in excess of 12 microns thick creating a decal that is usable for years. Each dot of ink is large and impenetrable. Other printers may try to sell you an offset or lithographically printed decal or sign … but don’t be fooled. These “higher DPI” reproductions will begin to fade immediately once the sun hits them.

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FLEXO PRINTING - This method of printing was created primarily for short-term and/or indoor use. With a maximum ink thickness of two to five microns, flexo printing is perfect for temporary promotional decals, service reminder statics and short-term use product labels. Communication Graphics also uses the flexo presses to print other innovative products including plush labels, flexible signage and mousestiks.

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UV INK – Communication Graphics’ UV inks feature the same vibrant pigments used in automotive paints. Most other label inks do not have a natural brilliance; therefore, some companies may spray a UV coating on the decal to provide an acceptable, but short-term gloss.

Clear laminations usually yellow over time, and clear coats continue their drying process once exposed to UV rays, causing edge curl and adhesion failure. CGI, however, uses UV light-cured inks. These inks are dried during the screen-printing process to a glossy sheen that is fade, chemical and light resistant.

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SUBSTRATES AND ADHESIVES - A substrate is the surface on which the ink is applied. From white vinyl to silver polyester, there are number of options from which to choose. Adhesives come in many different formulations as well from high-tack to heat resistant to low peel. Communication Graphics' account executives listen to YOUR needs and help you determine which is best for your application. Use the convenient chart below to get started.

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MATERIALS USAGE GUIDE

KEY	= Indoor Use = Indoors and Outdoors = Long Life = Short Life
Polyester (AKA “Mylar”)		Withstands many outdoor stresses.
Vinyl		Very weatherable, good resistance to UV light.
Polypropylene		For interior or bottle applications, good for short-term use.
Paper		For events, short-term use, etc.
Polyethylene		Durable in a rigid or flexible mil weight, withstands chemicals. Communication Graphics uses this material for affiliation cards, car tags, rulers, bookmarks and more!
Specialty Films		Laminates, shimmer cal, voidable stock and more, Communication Graphics can provide you with the most unique of substrates – call for more information.
Specialty Adhesives		From low tack adhesive for easy removal, to high temperature adhesive for hot surfaces, Communication Graphics will assess your unique needs and make recommendations for your consideration.

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SPOT COLOR VS. FOUR-COLOR PROCESS – Did you know that every four-color process image is simply a series of dots? In process printing, four dot colors (cyan, magenta, yellow and black) are used to produce the many shadings of an image. Process images can be screen-printed, but will display a larger dot pattern than traditional flexo, offset or litho printing.

For decals or signs that encounter intense light, rain, cold, heat or chemicals, screen-printing is the best choice … even if the dot pattern is apparent at close view. This process image will last longer and serve your brand better.

In spot color printing, there are over 1,000 Pantone colors from which to choose. During printing, the ink dots ‘fuse’ together to form a solid block of color. A very vibrant and long-lasting graphic image is the result, especially when screen-printed.

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APPLICATION METHODS – There are many methods to adhere your new static or label. Included here are some recommendations that have worked for many. If you’re concerned about removing paint or other such surfaces, it is best to test the decal in an inconspicuous place and use at your own risk.

Thermal Decal Application Recommendations (.PDF)
Decal Application Recommendation – Wet Method (.PDF)

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