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How to Select an Overlaminate

Spoilt for Choice!

Years ago, the limited range of vinyl overlaminating films simplified product selection. Used on everything from tanker markings to safety labels, a few polyester laminates were all that was available. Today, the range of products includes a variety of facestocks, adhesive systems and release liners.
Common facestocks include polyester, polypropylene, polyvinyl fluoride (PVF), polycarbonates, and cast and calendered vinyl. Although glossy overlaminates sharpen color contrast, matte finishes soften colors and contrast, thus hiding printing imperfections. Plus, matte finishes also minimize the glare of lighting.


Key considerations

Options facilitate selecting the right product for a specific application, but too many choices can complicate a purchasing decision. Picking the best overlaminate requires matching product performance characteristics to the application's demands.
The overlaminate, print media and printing method must be collectively selected as part of a total system solution. Also, duly consider the project's environment. Durability depends heavily not only on environment, but also upon the printing process and raw-material interactions with each other.

A process of elimination streamlines options. Here are some important considerations:

• What is the application? It's important to pick the right tool for the job. Whether the task involves floor graphics, perforated window graphics or fleet markings will dictate the appropriate overlaminate.
  
• What substrate will receive the graphics? Will it be smooth, such as flooring, an acrylic or polycarbonate sign face, or will the graphics be positioned over rivets or corrugations?
  
• What environment will the graphic endure? Will there be temperature extremes, UV light, water or pollution? Will it be subject to acidic or alkaline cleaning agents, or could it be exposed to vandalism, grease or road salts?
  
• Under what lighting conditions will the graphic be viewed?
  
• What are the job's durability requirements?
  
• Is the overlaminating film compatible with other components of the graphics system?
  

Printed fleet graphics

Public vehicles, such as buses, are common targets of marauding vandals armed with cans of spraypaint.
Specially coated overlaminates can protect graphics from this urban artistry, but for extremely demanding applications, expensive polyvinyl fluoride (PVF) overlaminate films provide the utmost protection.
(Table 1).

Table 1: Characteristics of PVF Overlaminates

Excellent for demanding applications Excellent outdoor durability Graffiti resistant Excellent UV protection Excellent abrasion resistance Very expensive

Tankers and cement trucks

Although vinyl overlaminates are usually best for vinyl markings, chemical tankers and cement trucks are an exception. For protecting markings subject to chemical damage, polyester overlaminating film was the best choice 20 years ago, and remains so today. Polyester exhibits outstanding chemical and temperature resistance -- features that also make it an excellent protective film for warning labels (Table 2). But, because polyester isn't conformable, it can't be used over rivets, corrugation or compound curves. Furthermore, it shouldn't be used to protect such flexible surfaces as awnings.

Table 2: Characteristics of Polyester Overlaminates

High strength Excellent clarity Withstand hot temperatures Excellent chemical resistance Outdoor durable Good abrasion resistance Rigid, inflexable

Floor graphics

Because floor graphics must withstand extraordinary abuse from pounding foot traffic, dirt, grease, grit and chemical cleaners, several types of overlaminates are designed for these applications.
Polycarbonate makes the best choice for floor applications because this tough, resilient film can withstand daily traffic, and its matte texture prevents slippage. However, polycarbonate film is expensive (Table 3). Thus, calendered vinyl overlaminate is an economical, but less durable, alternative. Whichever film you choose, all floor graphics should be laid to prevent edge lifting.

Table 3: Characteristics of Polycarbonate Overlaminates

Excellent for floor graphics, in-store graphics and exhibit graphics Withstand abrasion and rough handling When used for floor graphics, provide excellnt slip resistance When used for in-store graphics, velvet texture eliminates glare from overhead lights Thick rigid covering with excellent lay-flat characteristics

In store, P-O-P and exhibits

As digital printing has grown in the sign industry, so has the use of overlaminates for signage, interior-wall, tradeshow graphics and P-O-P applications.
Thick polycarbonate overlaminates are also often used for the protection of exhibit materials. This rigid protection offers excellent lay-flat characteristics, and its velvety texture eliminates any glare from overhead lighting. Polycarbonate can also withstand the rough handling encountered in tradeshow environments.
Vinyl overlaminates are offered in various finishes. These films cost more than polyester, but are easier to laminate and less prone to bubbles and edge lifting.
A cost effective alternative to polycarbonate or vinyl, polypropylene overlaminating films now include a variety of 2- and 4-mil facestocks in several finishes. For display graphics, 5- and 10-mil polypropylene films are also available (Table 4).

Table 4: Characteristics of Polypropoylene Overlaminates

Moderate temperature resistance Good clarity Good chemical resistance Good durability Can be used outdoors Scratch easily

Did the above article make you curious about the perfect laminate for YOUR applications?

Call NOW on 02 9568 6855 and ask for one of our friendly Account Managers. Our team is looking forward to finding the perfect solution for you.