How to Make Vinyl Graphics
Vinyl graphics are everywhere. Seen on vehicles, signs, machinery, banners, vending machines and store displays, this relatively new process has dominated an industry once run by painting and screen printing. The vinyl cutter is similar to a modified computer pen plotter, outfitted with a swivel knife rather than a pen. The graphics and lettering are designed on computer, and the cutter cuts through adhesive vinyl. Excess material is removed, leaving behind the lettering or design for application. With a modest investment in supplies and equipment, a little know-how and experience, you can set up a fun and rewarding hobby business.
Things You'll Need
- Vinyl cutter/plotter
- Computer
- Sign cutting software
- Roll or sheet of sign vinyl
- Premask application tape
- Vinyl application fluid
- Signmaker's squeegee
- Ruler or tape measure
- Razor knife or scissors
- Masking tape
- China marker/grease pencil
- Tweezers
- Glass cleaner
- Paper towels
Instructions
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Using sign software, design the lettering or graphic. Line-art images may also be scanned, and imported into the software. Sign software converts lettering and graphics into computer language which the vinyl cutter needs to operate.
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Load the roll or sheet vinyl into the cutter, in accordance with the manufacturer's instructions. Press the "print" or "cut" command on the software screen, and specify the installed cutter. Cutting will take several minutes to an hour, depending on the cutter speed and the complexity of the design.
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Cut the finished vinyl from the roll with scissors. Lay the vinyl on a flat table, and begin the weeding process. The weeding process involves removing all surrounding vinyl from inside and outside the design. Tweezers help in removing small sections, and to peel up edges of larger sections. The desired result is to have the design remain on the vinyl backing sheet, with all excess material removed.
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Install premask over the entire weeded design. Premask is a light-tack, translucent masking tape, and is available in many widths. For larger designs, it is easier to use several smaller widths than one large premask. As the premask is applied to the design, burnish with a signmaker's squeegee to promote positive adhesion, and push out large air pockets.
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Prepare the sign surface by cleaning thoroughly with glass cleaner and paper towels. If installing on a vehicle, use car wash detergent. Measure the area where the design will be located, and make guide marks with a grease pencil (also called a China marker). Position the premasked vinyl graphic over the area, making sure the graphic is square, and all guide marks are visible. Tape the top side of the graphic in place, so that a hinge is formed, and the graphic hangs freely.
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Roll the graphic upwards, stopping at the masking tape hinge, and spray vinyl application fluid on the sign surface. Slowly remove the backing sheet from the vinyl as you work. The top surface of the vinyl should be stuck to the premask as the backing is removed, with the vinyl's adhesive side exposed. Working top to bottom, slowly roll the vinyl onto the surface, using the signmaker's squeegee to burnish, force out application fluid and remove bubbles. When wet, the fluid acts as an aid to control air bubbles and allow the vinyl to be positioned easily. The application fluid will enhance binding after evaporation. After the vinyl has been applied, carefully remove the premask. Do a final burnishing with the squeegee, remove excess fluid with paper towels, and the vinyl graphic is complete.
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Tips & Warnings
Higher quality vinyl increases ease of cutting and application. Avoid freezing or very hot temperatures when installing vinyl outdoors.
Use caution when using razor knife and other cutting tools. Keep hands away from moving plotter blade, even if it is stuck. Always unplug when servicing.
