How to Double Layer Vinyl Graphics

Multi-layered vinyl graphics supply the bulk of signs, store windows, city bus art and vehicle graphics we have surrounding us every day. Unlike printed vinyl graphics, multi-layered vinyl graphics must have each included color cut and weeded from single-color vinyl, then masked and assembled with the other colors to create the finished graphic. Certainly more goes into a simple two color vinyl graphic than most people think.

Difficulty: Moderate

Instructions

Things You'll Need:

• A computer with vector-based design software installed
• Vinyl Plotter
• Self Adhesive Vinyl Film
• Masking Paper
• Masking Tape
• X-Acto Hobby Knife
• Plastic Squeegee
• Application Fluid or Mildly-Soapy Water (optional)

Outputting Your Graphics

1. Using a vector-based design program, create your artwork in two colors. Make sure to adjust your art for color overlap and/or trimming. For example: If you have a yellow shape with a black outline, you can either adjust the art so the yellow vinyl would sit on top of a larger black vinyl piece, or trim the black to be just the outline around your yellow vinyl.

2. Send your finished vector art to your vinyl plotter to cut the graphics . The actual graphics may be difficult to see on the vinyl stock from a distance.

3. Lay the two cut graphics out on a table large enough to allow them to lie flat. Examine them closely to make sure the plotter cut all the way through the vinyl layer, but did not damage the backing paper.

Vinyl Processing

4. Remove all the excess, non-graphics vinyl from your sheet, leaving only the cut graphic behind. This is the most meticulous and detail-oriented step in the process. This is due in chief to the delicateness of the thin vinyl film being "weeded" of its unnecessary bits and pieces.

5. Cover the top layer of vinyl with masking paper. The "top layer" being whichever color will be applied on top of the other." There are clear masking papers available if you have difficulty seeing through regular masking paper, or if detailed alignment is needed.

6. Align your colors on a light table if available. Once aligned, tape down the bottom layer on all sides. Making sure not to put any tape over the vinyl graphic, or any area the top color may hit. Tape down the top color on one side only. Make sure you tape along the edge in one long piece instead of a few short, non-touching pieces. This tape should act like a hinge for the top layer.

7. Flip back the top layer and carefully remove the backing paper, making sure the graphic is retained by the masking paper. Flip the top layer back over and slowly, methodically smooth it down with a squeegee. Start at the "hinge" and work your way across.

8. If you layered the two colors dry, you're ready to un-tape it from your table and apply your newly-finished, two color graphic. If you wet-applied the top layer, you may need to remove the masking paper, dry the finished graphic and apply new masking paper.

Tips & Warnings

• You can use application fluid or mildly-soapy water when aligning/combining layers to make slight repositions easier. Use a felt squeegee, or a new sock wrapped around your plastic squeegee to smooth out your graphic while assembling.
• Self-adhesive vinyl film can be very tricky to work with for first-timers. It has a tendency to stick to itself very easily, and once stuck proves difficult to fix without irreparable damage occurring.