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The vinyl comes in large, typically single-color rolls that have a paper backing. The cutter, built very much like a plotter with a knife instead of a pen, cuts through the vinyl but not through the paper. It is actually very impressive to watch!
WEEDING - Unfortunately, the promotional photo above is not a completely accurate representation of how the cutter works. The vinyl comes off the cutter looking more like the top example below:
Once the cutting process is complete, portions of the vinyl must be removed or "weeded". In the middle example above, the letters have been weeded out to leave the red box around the them. In the bottom example above, the vinyl makes up the red letters and everything else has been removed.
When you consider the cutter photo again, you can imagine how tedious the weeding work can be!
Just think about hovering over this large piece of vinyl, removing all those little details from the bicycle tires and rider! (The weeding process is done by hand.)
MASKING - Once the vinyl has been weeded and is ready for application on the substrate, a large piece of masking tape is applied over the vinyl to lift it off of the paper backing.
APPLICATION - The vinyl has an adhesive backing, so the masked vinyl is then positioned on the sign substrate where it permanently adheres.
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The photo above shows you just what it would look like if we were printing the photo using a vinyl printer.
The printer uses either solvent or eco-solvent inks to print the photo on special commercial-grade white vinyl or banner material.
The inks and vinyl are rated for outdoor exposure. Like the cut vinyl, digitally printed vinyl has an adhesive backing and is applied directly to the sign substrate.
Digital printers and inks are very expensive. Depending on size and capabilities, they can cost from $10,000 to more than $100,000!
Depending on the printer, the print resolution will typically range from 300 to 1400 dpi. Only high-end printers will print in near-photo quality. But, even though the printing is not photo-quality, it still looks very nice.
Of course, unlike a photograph, these printouts are weather proof!
Depending on your needs, your sign company can use the entire piece of vinyl to make your signs OR they can cut out just the graphics and then apply them. Accuracy of the cut will depend on the complexity of the graphics / photograph.
MASKING - Once the vinyl has been printed and given time to properly cure, a large piece of masking tape is applied over the vinyl to lift it off of the paper backing.
APPLICATION - The vinyl has an adhesive backing, so the masked vinyl is then positioned on the sign substrate where it permanently adheres.
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Vinyl cutting software requires vector-based graphic files. Vector-based files include .eps, .ai, or .wmf. However, just because a file has one of those extensions does not mean it is truly vector based. In fact, if you are not familiar with vector-based files, there is a good chance your file is not vector-based. Your sign company can tell you if they can use the file or not.
Additionally, even if a graphic is in vector-format, it may not be "cut-ready". Here is an example of a .eps file. The left version is what the file would look like if printed. The right version shows it in "outline" view.
The outline view on the right is what the software and cutter use to cut the vinyl. The cutter knife will follow all of the lines you see. If this graphic were cut "as is", it would be sliced into too many pieces and would not be usable.
This is why your sign shop may charge an additional fee for graphics work even though you have a vector-based file.
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As long as your sign company has the necessary software, just about any graphics file will work for digital printing. Usable files include .jpg, .jpeg. .psd, .eps, .ai, .wmf, .gif, .bmp and many more.
However, it is very important that the file is large enough and have high enough resolution to print properly.
Let's take this cute picture as an example. Looks good enough right?
But, when the sign shop enlarges it to fit on a 12 inch by 24 inch sign, the clarity of the photo is greatly reduced.
Experienced signs shops can enhance photos to some extent, to give the appearance of improved clarity once enlarged. But it is best to give your graphic to your sign specialist first, to see if they can use it for your project.
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| The cost of equipment and materials for the cut-vinyl process are much less than for digitally printed signs. That means the cost of the signs will typically be much less.
The colors are infused within the vinyl and typically make a more durable sign.
Designs using cut vinyl are typically very simple. Photos and highly detailed graphics are impossible to create using cut vinyl.
Although there are some exceptions, most vinyl comes in a single, solid color. That means gradients, gradual shading, color fading and soft drop shadows cannot be recreated using vinyl.
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Digital printing equipment and materials are very expensive, which will be reflected in a higher price for your signs.
The colors (ink) are applied to the surface of the vinyl and, although they are specially treated for outdoor exposure, they are not as durable and will fade more quickly.
If a graphic is high enough resolution, it can be used on a sign. Printing resolution depends on the printer, but don't expect photo-quality results. But, they will look great from just a few feet away...which is acceptable for a sign. (Of course, the trade-off is that the printed sign is weather-proof.)
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What Is Cut Vinyl? 
