Expand Vol. 2 No. 7

World of Displays, Part 1

Building better tradeshow displays with the right combination of media, laminate, and ink... This month, aqueous-based solutions for front-lit and backlit pop-up booths are on the menu, along with helpful hints for error-free production.

Though solvent and UV-curable printers have made huge inroads as preferred printing platforms for wide-format graphics, aqueous-based printing is still the norm for trade show graphics. Therefore, this series of articles begins with a rundown of aqueous-based solutions and combinations for trade show graphics, along with the benefits and limitations of each.

In the coming months, we'll cover aqueous-based solutions for retractable banner stands, mounted graphics, vinyl banners, and solutions that don't require lamination. In subsequent months, we'll cover a bevy of possibilities for all types of booth configurations using solvent and UV-curable printers.

But first, here are the basic production guidelines to implement on the front end of the process to ensure you don't get caught on the back end with graphics that fail while they're out and about on the trade-show circuit. There are few things more hateful than a customer's desperate (and usually angry) phone call from some trade show in Timbuktu demanding replacement graphics right away…

Drying time: For ink, the recommended drying time before lamination is at least 24 hours. If the ink is dry to the touch after 24 hours, and not at all tacky, it should be good to go. Furthermore, be careful not to oversaturate the graphic. Profiles, settings, and file management are extremely critical.

Cure time: As with ink, the laminate's adhesive should be given 24 hours to cure before graphics are trimmed and rolled. Given time constraints in production, the full 24 hours may not be possible, so allow at least two hours. Still, the longer you can allow the adhesive to cure, the better off the graphics will be. If the adhesive is not given enough time to cure, it will not bond properly to the print, causing tunneling, delaminating, and edge lift. The adhesive’s cure time is the most important factor that determines the strength of the graphic.

Cutting and trimming: Always cut through the softer material first, when applicable. Use a sharp blade and trim the graphics with a straight edge at a 90-degree angle on tempered glass. Self-healing mats and other softer surfaces will compromise the bond between the laminate and the print.

Rolling graphics: Always roll the graphics with the thinnest material facing out. For instance, when using LexJet 6.5 Mil Opaque Display Film with 15 Mil PreLume DisplayFlex (PSA), the Display Film should be on the outside as the graphic is being rolled up for shipment. When both materials are the same thickness, always roll them the same way every time, and don't roll them in the reverse direction to make them lay flat. Also, roll the graphics at a minimum 12-in. diameter. Make sure to provide the customer with simple rolling and packaging instructions.

Sledding: Use a sled when you laminate. A sled – which should be made of a hard substrate like Masonite, acrylic, or aluminum – helps ensure even pressure across the web. Apply a release liner to the sled to prevent adhesive build-up. The release liner will allow you to easily clean off the adhesive.

Eliminating curl: If you're having a problem with curling when you apply pressure-sensitive laminates and backers, either reduce the speed of your take-up reel or put less pressure on the rollers.

Printing on film: The best material choice for rollable trade-show graphics is an inkjet film, such as polycarbonate, polyester, and polypropylene. Fibrous paper tends to split, tear, and curl.

Magnetic and Velcro-Backed Pop-Up Booths: Front Lit/Reflective

The following product solution recipes begin with the ideal application for long-term, multiple use that provides the most visual impact for your customer. The material solutions listed are compatible with all types of UV and dye aqueous-based printers. The relative quality, durability, ease of use, production efficiency, and performance consistency decreases as you go down the list. The point is to match the solution to your customer’s budget and needs.

Also keep in mind the fact that magnetic pop-up booth graphics should be at least 19 mils thick (media and laminate together, or media and backer) in order for the graphic to hold its shape. Velcro-backed pop-up booths can hold material combinations as low as 10 mils thick.

LexJet Clear PreLume HD w/ Edge Strips with 10 Mil or 15 Mil Coex PreLume Opaque White Backer (PSA): This is a two-step reverse-print solution on the brightest white combination available in the industry today. Moreover, the graphics can be rolled up indefinitely without being damaged, and the textured matte finish provides a professional, non-glare look. For end caps, use the 5 Mil Coex PreLume White Backer. This is the exception to the 19-mil rule since you want the graphic to be flexible enough to roll around the end cap. For mounting LexJet Clear to Sintra, acrylic, and other mounting substrates, substitute the backer with a GraphicMount Adhesive.

LexJet 6.5 Mil Opaque Display Film with 15 Mil PreLume DisplayFlex (PSA) or 15 Mil PreLume ExhibitGuard (PSA): This combination of a 100-percent opaque front-print film and a co-extruded, co-polymer film coated with the exclusive PreLume adhesive system for brighter whites offers fast, easy production utilizing durable, textured materials. For end caps, use the 10 Mil PreLume DisplayFlex.

4 Mil White Polyester with 15 Mil PreLume DisplayFlex (PSA): For magnetic-backed pop-up booths, this is a two-step production solution that is durable and attractive, though not quite as durable as the previous two solutions.

LexJet 8 Mil Satin Polypropylene with 10 Mil PreLume DisplayFlex (PSA), 15 Mil PreLume DisplayFlex (PSA), or 15 Mil PreLume ExhibitGuard (PSA): The satin film allows for a slightly different look than a matte finish that some customers prefer. As with the other solutions, the laminates are textured and durable, the process is simple, and the graphics will not tunnel or de-laminate. This combination is suggested for magnetic-backed pop-up booths only.

8 Mil ImagePro Photo Gloss or Satin, or 7 Mil High Performance Photo Gloss or Satin, with 10 Mil DisplayGuard VI, 10 Mil DisplayGuard Ti, or 7 Mil CrystalEmboss, along with 5 Mil or 10 Mil White Backer or a 10 Mil LightBlock Backer: These combinations, which provide a front laminate and a backer to sandwich the photo paper, are less expensive, but there is a slight sacrifice in overall durability since the paper could eventually split.

Magnetic Pop-Up Booths: Backlit Panels and Headers

10 Mil LexJet UltraBright with 10 Mil PreLume DisplayFlex or 10 Mil PreLume ExhibitGuard: Reverse print on the backlit polycarbonate, and combine with a 10 Mil laminate behind it for additional protection and rigidity. This is a durable, two-step, textured solution perfect for backlit panels and headers. For end caps, use 5 Mil PreLume DisplayFlex for the backer. As with frontlit LexJet Clear, substitute GraphicMount Adhesives for the backer when mounting to substrates like acrylics. This solution is only for dye-based inks since UV inks will not migrate into the coating. The following backlit combination is best for UV inks…

7 Mil AquaLight with 15 Mil PreLume DisplayFlex or 15 Mil PreLume ExhibitGuard: This is the front-print solution utilizing a backlit film laminated with a co-extruded, co-polymer film, which is coated with the PreLume adhesive system to ensure brighter whites. For end caps, use 10 Mil PreLume DisplayFlex.

If you have any questions about these combinations and applications, please contact your LexJet account specialist who has been specially trained to find the perfect custom solution for your customer.