Melissa Donovan
Addressing
Solving
Stunningly Printed
Is there anything more fulfilling for a print service provider (PSP) than a stunningly printed graphic? It’s the epitome of a job well done; an example of the type of success achieved after committing to hours of labor, running through feet of media and liters of ink.
…an outcome you can visually appreciate alongside enjoying the hard work that went into it—until the next order comes in.
Visually appreciating the work can mean witnessing it out and about while running an errand locally or in the case of our Application Spotlight this month, Hitting the Boards, seeing it televised nationally. The Look Company was tasked with creating multiple square feet of printed graphics for the NHL’s Winter Stadium Series at the very beginning of 2026. The finished product not only left the PSP proud but provides them with an attention boost in terms of its capabilities.
The Look Company relies on proprietary printing technology to reach high levels of productivity for high-profile jobs like the recent one for the NHL, but that doesn’t mean that other technologies aren’t available to achieve the same result. For example, three-meter wide roll-to-roll devices are a hot topic of conversation right now and High-Quality Productivity dives into this in more detail.
This issue also looks at paint protection films for vehicle wraps, workflow solutions, ink options for direct to garment/direct to film printing, and includes a preview of the ISA International Sign Expo held in Orlando, FL this April.
At the show view the latest and greatest technologies and plan your next investment, which hopefully leads to a stunningly printed graphic—an outcome you can visually appreciate alongside enjoying the hard work that went into it—until the next order comes in.
EDITOR IN CHIEF
Thomas Tetreault ttetreault@rockportpubs.com
EDITOR
Melissa Donovan mdonovan@rockportpubs.com
ASSOCIATE EDITOR
Cassandra Balentine cbalentine@rockportpubs.com
WEB EDITOR
Melissa Mueller
ART DIRECTOR
Sarah M. White swhite@rockportpubs.com
CONTRIBUTORS
Marco Boer, Olivia Cahoon, Tim Greene, Melinda Tetreault, Amber Watson
ADVERTISING SALES
PUBLISHER
Thomas Tetreault
NATIONAL ACCOUNT EXECUTIVES
Amanda Doyon adoyon@rockportpubs.com 978-921-7850, Ext. 170
Subscribe online at digitaloutput.net
CORPORATE & PUBLISHING OFFICE
300 Newburyport Turnpike, Ste. 11 Rowley, Massachusetts 01969
ROCKPORT CUSTOM PUBLISHING, LLC
CHAIRMAN
Jeffrey Jensen
PRESIDENT & CEO
Thomas Tetreault
Digital Output is published monthly by Rockport Custom Publishing LLC. ©Rockport Custom Publishing, LLC 2026. Reproduction by any means of the whole or part of Digital Output without written permission from the publisher is prohibited. Views expressed in the editorial pages do not imply our endorsement.
Vendors: We welcome your product news. Include prices, slides, photos, and digital files with your press release. Please forward product samples and media kits to Reviews Editor, Digital Output, 300 Newburyport Turnpike, Ste. 11, Rowley, MA 01969. We cannot be responsible for unsolicited product samples.
SUBSCRIPTION RATES
U.S.: $82.95 per year; $165 for 2 years; single copies: $6.95; Canada and Mexico: $99.50 per year (U.S.D.); Other international subscriptions: $275 per year (U.S.D.)
POSTMASTER
Please send address changes and form No. 3579 to: Digital Output, 300 Newburyport Turnpike, Ste. 11, Rowley, MA 01969. Periodical Class postage rates paid at Rowley, Massachusetts and additional mailing offices.
Cheers, Melissa Donovan, editor mdonovan@rockportpubs.com
CHANGE OF ADDRESS NOTICE
Six to eight weeks prior to moving, please clip the mailing label from the most recent issue and send it along with your new address (including zip code) to: Digital Output magazine, change of address notice, 300 Newburyport Turnpike, Ste. 11, Rowley, MA, 01969. Attention: Circulation Department.
1) Canon, booth 2523, demonstrates the new Colorado XL-series. 2) Nekoosa, booth 1818, showcases materials that make production faster, installation easier, and yields consistently reliable results.
TFind Your Spark ISA International Sign Expo
by Digital Output Sta
he ISA International Sign Expo takes place April 8 to 10, 2026 at the Orange County Convention Center in Orlando, FL. The show’s host, the International Sign Association (ISA), encourages attendees to “find your spark” while at the event—view hands‑on demon‑ strations and network with exhibitors to grow business. Here, vendors share showcased products and provide information about their solutions and services.
Canon U.S.A., Inc., booth 2523, showcases the new Colorado XL‑series and the Colorado M‑series, the Ari‑ zona 2380 GTF, and the imagePROGRAF GP‑4600S with MFR. The Colorado M‑series is also featured at the Colex booth. In addition, Canon showcases finishing solutions, including a 24‑inch Summa cutter with stand and the Colex SXC1732 cutting system, demonstrating a complete, end-to-end workflow. INFO# 185
GBC/SEAL, booth 1800, demonstrates its precision‑ engineered, high‑production SEAL 65 Pro MD laminator that is capable of running thermal film at two to three times the speed of other laminators. Also featured is the SEAL 62 Base Laminator, which is ideal for mounting and
laminating pressure‑sensitive graphics up to 61 inches in length and the first fully automated desktop laminator from GBC—the GBC Foton 30. Also on display, innovative GBC and SEAL products and the unveiling of the fastest laminator from GBC. INFO# 186
Graphic Finishing Partners (Gfp), booth 1546, exhibits the 663‑TH Production Top Heat Laminator, featuring Smart Finishing Technology. This laminator includes a digital microcontroller system, a touchscreen user inter‑ face, swing-out supply film shafts, inline rotary slitters, a rear take‑up, and a roll label printer. Gfp also showcases the Production 563TH‑4RS Top Heat Laminator, the Professional 363‑TH Top Heat Laminator, and the 220‑C Tabletop Laminator. INFO# 187
Nekoosa, booth 1818, presents materials that make pro‑ duction faster, installation easier, and yields consistently reliable results. NextBond High Bond Opaque delivers strong adhesion and full blockout coverage on difficult surfaces. Nekoosa’s Wide Format portfolio adds dependable print media, overlaminates, mounting films, and specialty materials that support signage work. INFO# 188
Photo Tex Group, booth 936, cel ebrates 23 years distributing Photo Tex self‑adhesive media. It is en gineered to cover walls, windows, doors, and floors. The third genera tion patented adhesive on Photo Tex performs on today’s paints, withstands outdoor environments, and meets “green,” non‑toxic, LEED standards. INFO# 189
Quality
Media and Laminating Solutions (QMLS), booth 1584, highlights the Kala Mistral 1650 laminator. Engineered for precision and consistency, the Mistral deliv ers smooth, bubble free lamina tion. Its automatic pressure calibra tion ensures uniform results across the full 65 inch working width, while adjustable heated top roller temperatures and fast production speeds support wrap films and overlaminates. INFO# 190
Shark Finishing Machinery, booth 1084, features two of its latest innovations—the SB 660ACF Perfect Binder and the SDDC 1800A Digital Die Cut ter. The SB 660ACF features automatic spine and hinge scoring with integrated cover feeding, delivering consistent, professional-quality books with minimal setup. The SDDC 1800A Digital Die Cutter offers fast, flexible cutting for on demand applications. INFO# 191
Summa, booth 2300, focuses on precision, performance, and productivity. Visitors at its booth get a firsthand look at the S Series vinyl cutters, including dedicated direct to film models. Additionally, it features the entry level V Series Optima cutter. The company also demonstrates the flagship F1625
flatbed cutter. With exceptional versatility and precision, the F1625 is ideal for handling a range of rigid and flexible materials while maximizing workflow ef ficiency. INFO# 192
Supreme Color Graphics, booth 3034, is a national wholesale digital printer working exclusively with trade partners. From ban ners and yard signs to magnets, standees, floor signs, and beyond, it offers a broad product lineup designed to help you “say yes” to more projects. INFO# 193
swissQprint, booth 2511, runs the Nyala 5 flatbed live. It pro duces consistent flatbed quality and high impact neon and other
applications under real produc tion conditions. Visitors can see how a rigid platform, precise ink management, and configurable architecture reduce risk, limit waste, and keep operations run ning predictably. INFO# 194
Learn and Party
The ISA International Sign Expo is always an educational trade show but don’t forget to have some fun while you are there. ISA ROCKS! is a highlight of the overall event—the party features an open bar, food, and live enter tainment. This year it takes place at 6:30 p.m. on Thursday, April 9 at the Pointe Orlando. Visit signexpo.org to get your tickets before they sell out. D
Finishing Simplified: KalaXY Automatic XY Cutters from Supply55
Engineered and manufactured in Europe, the KalaXY cutter/trimmer reduces labor and increases profits by eliminating the time-consuming task of manually cutting printed digital images. Our line of automatic XY cutters are the ideal solution for processing a wide range of media including wallpaper, paper, direct to film, canvas, laminated/encapsulated films, banner material, polycarbonate, and other non-woven roll goods. Increase your output while reducing operation costs with KalaXY Cutters. For more information visit supply55.com, call 734-668-0755, or email sales@supply55.com. Simplify your finishing operation today with KalaXY cutters/trimmers. INFO# 1
SUPPLY55, INC.
Hi ing the Boards Graphics for the NHL Stadium Series
by Melissa Donovan
The Look Company is a global force in designing, planning, printing, and installing visual graphics for retail and sporting events. High-profile clients include FIFA, Formula 1, Jaguar Land Rover, Lululemon, Mattress Firm, MLB, NHL, and Walmart. In business since 1998, when it was first known as The Fabric Communication Network, today The Look Company operates out of Barrie, ON, Canada, with additional offices in Doha, Qatar and Saint Pierre en Faucigny, France—a total global manufacturing space of 380,000 square feet.
Updated Abilities
The large-scale visual branding company has never shied away from technological advancement, continually investing in the latest and greatest print hardware to meet its clients’ needs. One of those goals, according to Jacob Burke, global
CEO, The Look Company, is creating large-scale graphics at a higher visual quality.
“There’s no reason that the large-scale graphics seen on game day or while shopping in store should be lower quality based on existing industry standards,” notes Burke.
Over the years key staff members’ collective knowledge of the printing process, particularly textile dye-sublimation (dye-sub), led to the realization that The Look Company team was capable of designing and implementing its own printing device that could yield large-scale graphics at high visual quality.
With our experience in dye-sub we get these really deep, vibrant, punchy colors that are also very camera friendly.
— Jacob Burke, global CEO, The Look Company
It’s spent the last decade perfecting a wide format dye-sub fabric printer that offers eight-color printing at 600 dpi resolution. According to the company, this
means that graphics are printed at twice the color gamut achieved by standard industry printing, while decreasing printing times and increasing energy efficiency.
“It’s a balance between quality and speed. We fine tuned the eightcolor printer and resolution, in line with the speed. It makes it so we are comfortable turning things around quickly but offering quality at that speed,” says Burke.
All of The Look Company’s locations are outfitted with these new printing capabilities, allowing the print provider to operate globally and ensure consistency. This is especially important when hitting brand colors.
Printing at Scale
One of the first jobs that benefited from the updated dye-sub fabric printer was for the NHL 2026 Navy Federal Credit Union Stadium Series, which took place on February 1, 2026 in Tampa, FL with the Boston Bruins playing against the Tampa Bay Lightning. The NHL is a repeat client, with The Look Company creating signage for such events like the 2022 Heritage Classic.
The Stadium Series is a great example of what The Look Company accomplishes on a frequent basis, as Burke cites sporting events take up about half of its business—and probably the part that gets the most publicity because of the fandom attached to it.
Fandom is important because team colors must be just right, with no room for error. This is where the dye-sub printer’s capabilities shine.
“You have to consider the team’s logos—those are tried and true, have been around for decades in some instances. It’s very personal at that point and the fans notice,” points out Burke.
Then there is the added level of ensuring the colors are correct for whichever new logo the NHL designs for the Stadium Series that year. Between that new design and the two teams’ branding, expectations are high. The NHL expects The Look Company to match every color.
Traditionally, sporting event graphics include PVC-based materials, which according to Burke can be challenging. “Sometimes there is terrible glare. Especially with events that take place outdoors— there’s the sunset, sunrise, and clouds to contend with.”
Working with a fabric instead, these issues almost disappear. The Look Company engineers its own polyester-based materials. Using a natural fiber, once printed the fabrics are bright, vibrant, and feature colors that stay true at all times, at all angles, without glare.
Combine the fabric with the print provider’s updated dye-sub printer and the result is flawless. “With our experience in dye-sub we get these really deep, vibrant, punchy colors that are also very camera friendly,” explains Burke.
For the 2026 Navy Federal Credit Union Stadium Series, The Look Company produced all of the stadium branding found throughout Raymond James Stadium—banners around the rink, wayfinding signage, soft signage, media
interview backdrops, graphics on the exterior of the stadium, and more. A total of 200,000 square feet of graphics were printed.
Planning for events of this scope usually starts a year in advance, strategizing with the selected city and venue, and engineering concepts based on direction from the NHL. From initial design through production and installation, the full process for the 2026 Stadium Series took around six months.
Quality and Speed
The Look Company’s work for the NHL is a visual representation of its updated printer’s capabilities. Seeing the final product come to fruition—on a global scale—is a fantastic achievement for this nearly 30 year old company. D
Right-Size Delivery
Cartridge Versus Bulk Ink Delivery Systems for DTG/DTF
by Cassandra Balentine
Direct to garment (DTG) and direct to film (DTF) printers operate with bulk or cartridge ink delivery systems.
The best option for your organization comes down to volume, maintenance capacity, and business model, according to Marc Vila, director of marketing, ColDesi, Inc.
The choice is largely dependent on production volume and specific customer requirements. “Bulk ink systems are best suited for high-volume production environments, offering lower cost per print and reduced downtime due to fewer ink changes. Cartridgebased systems, on the other hand, typically have a lower initial investment and are
well suited for lower volume or entry-level operations; however, they require more frequent cartridge replacements, which can increase ongoing operational costs and interrupt production,” offers Gabriel Crumpler, TA segment specialist, Mimaki USA, Inc.
Compare and Contrast
When it comes to selecting an ink delivery system for DTG or DTF, Timothy Check, senior product manager, Professional Imaging, Epson America, Inc., points out that it’s not a simple “either/ or” choice. It really comes down to how the printer is used on a day-to-day basis.
…the choice between bulk and cartridge ink delivery systems should be driven by production volume, operator skill level, environmental controls, and tolerance for maintenance… — Adam Tipre, owner, PrinterBiz
“Vendors need to consider both production and quality needs when choosing between a cartridge
Mimaki offers various devices used in the production of customized goods.
or bulk ink system,” suggests Mike Davis, application specialist, Roland DGA Corp.
In general, Vila feels that if you’re running a high-output shop, bulk ink makes sense. This will have a lower cost per print and fewer refills. If you’re printing at a smaller to medium scale, cartridges are cleaner, easier, and more reliable with less babysitting. “It’s not about which system is ‘better,’ it’s about what fits your workflow.”
Taylor Landesman, VP, Lawson Workhorse Group, says the printer’s engineering/structure dictates the ink delivery system and whether it uses proprietary RFID-chipped cartridges versus bulk tanks.
The decision should account for a vendor’s primary operational priority and their ability to commit to rigorous, daily maintenance.
“Cartridges are the best choice for beginners, high-mix/low-volume shops, or any shop where labor dedicated to maintenance is expensive or unreliable,” suggests Ayden Tran, digital marketing manager, Ricoh DTG. “Choose bulk if prioritizing lowest consumables cost per print above all else, a very high daily print volume that uses ink quickly, and a dedicated, highly-trained technician performing daily, time-intensive maintenance.”
The choice between bulk and cartridge inks largely depends on a print provider’s level of experience and where they are in their production journey, according to Scott Donovan, North America commercial leader, DuPont Artistri.
“For companies new to DTG or DTF, cartridge-based systems can be the easiest way to learn the process and get up and running quickly. As printers become more knowledgeable and confident, they may choose to convert an existing system to bulk ink or invest in a new one to gain greater flexibility and cost control,” adds Donovan.
Considering Cartridges
Several advantages are associated with cartridge-based ink delivery systems for DTG and DTF.
Generally speaking, cartridgebased systems provide more consistency for a printer, as the inks packaged in cartridges are manufactured to high standards, notes Davis.
Additionally, cartridges operate in a closed-loop system. “The closed-loop nature of cartridges eliminates the risk of introducing dust or debris into the lines during the refilling process, which is
a common cause of nozzle deflection,” offers Landesman.
Cartridge systems shine when it comes to simplicity and consistency. “Because the ink is sealed and degassed issues such as micro bubbles that can lead to nozzle loss are avoided. Cartridges are also clean and easy to replace—no mess, no fuss,” explains Check.
Because cartridges are typically vacuum sealed, Landesman says this protects ink from oxidization and evaporation. “This is critical for white ink, which is prone to sedimentation and viscosity changes when exposed to air.”
“Less exposure to air means fewer clogs,” asserts Tran.
Cartridges typically incorporate internal filtration, degassing control, and controlled agitation, which helps preserve ink integrity and minimizes the introduction of contaminants into the printer. “This reduces the frequency of manual intervention, stabilizes
nozzle performance, and lowers the overall maintenance burden,” offers Adam Tipre, owner, PrinterBiz, a DTG Connection Company.
Additionally, integrated RFID chips provide high-accuracy ink tracking and prevent the accidental mixing of incompatible ink batches or expired fluids, notes Landesman.
“One major advantage is having a single point of contact for support, since the printer, ink, and consumables are all part of the same eco-system,” notes Donovan.
Overall, cartridges offer plug-andplay convenience, reduced chances for user error and contamination, as well as lower maintenance. Vila feels these systems are well suited for small- to mid-size shops.
There are downsides to cartridge systems to consider.
First is cost. Tran suggests that cartridges tend to carry a higher cost per milliliter compared to bulk ink.
This increased expense is “due to the additional engineering and packaging involved,” agrees Check.
Davis adds that cartridges need to be replaced more often than bulk ink refills.
Cartridge-based systems have limited ink capacity, making them less practical for long or continuous production runs. “Additionally, as business grows and print volumes increase, cartridge systems become less efficient to scale and can be less cost effective compared to bulk ink systems,” admits Crumpler.
Inventory overhead can also be a disadvantage. “Managing a fleet of small cartridges requires more storage organization and more frequent procurement cycles compared to stocking a few five-liter jugs,” shares Landesman.
“While cartridge systems may carry a higher nominal ink cost, many vendors find that the reduction in downtime, maintenance labor, and wasted ink and media offsets the price difference. In high-reliability or low-maintenance environments, cartridges often deliver a lower total cost of ownership and more predictable production output,” adds Tipre.
Bulk Pros and Cons
Bulk systems also bring benefits for DTG and DTF.
Landesman points to three main advantages of bulk ink delivery systems—lowered operating costs, reduction of single-use plastics, and refilling abilities.
“Bulk ink is more economical, often reducing the cost per milliliter by 60 to 80 percent compared to cartridges. This is the biggest factor in achieving a rapid return on investment,” says Landesman.
Landesman adds that bulk systems allow for “on-the-fly” refilling. In some configurations, ensuring that a high-capacity run isn’t interrupted by an “ink out” error mid-print. It also eliminates any RFID chip reading/resetting errors.
Davis agrees, confirming that an advantage of bulk ink systems is that they require fewer refills than cartridges.
2) The PrinterBiz UNINET DTF Xpress Printer is a high-performance DTF printing solution offering high efficiency and cost savings.
Check believes that bulk ink systems are all about flexibility and cost savings. “They allow users to have an abundance of ink on hand, generally at a reduced cost since the users are not paying for the materials required to manufacture individual cartridges or the microchips included.”
Vila notes that the lower cost per milliliter afforded by bulk ink delivery systems is ideal for production-heavy businesses because it’s easier to scale with bigger runs.
Since bulk systems deliver a lower cost per liter, this also reduces operating expenses for higher volume or more experienced print providers, adds Donovan.
The downsides to bulk systems involve maintenance considerations. “High exposure to air/humidity leads to faster degradation, pigment crystallization, and potential clogging issues,” cautions Tran.
“You do not want to have too much on your shelf as it can settle and/ or separate,” says Landesman.
“You need a team that stays on top of cleaning if you’re not printing consistently. Bulk ink can clog easier and cost you downtime. Users must be diligent about storage and refill standards,” warns Vila.
Maintenance includes monitoring and manual daily intervention— stirring, cleaning, filling—to prevent pigment separation and clogs, notes Tran.
Bulk ink relies on open or semiopen refill processes, which
increase the risk of airborne contamination, particulate ingress, and moisture exposure. “Even microscopic contaminants can disrupt ink flow, interfere with dampers and filters, and accelerate nozzle deflection or clogging—particularly in white ink systems where pigment density is higher. This results in more frequent clean cycles, elevated ink consumption during maintenance, and increased wear on printheads,” explains Tipre.
Bulk systems place greater emphasis on operator consistency and environmental control. “Variations in refill technique, agitation methods, storage conditions, and temperature stability can introduce inconsistencies in ink viscosity and pigment suspension. Over time, this can lead
to uneven print density, color shift, and premature component failure,” adds Tipre.
Vendors should evaluate the entire ink delivery ecosystem. “While bulk and refillable cartridge systems can appear attractive from a cost standpoint, they introduce variables that can negatively impact print stability, maintenance requirements, and overall operating efficiency,” suggests Tipre.
Bulk systems are not ideal for low or inconsistent production volumes, as ink may remain in the lines too long, expire, or require frequent purging when the printer is idle. “Bulk ink systems carry a higher risk when issues occur, since problems such as contamination or system failure
can affect a larger volume of ink,” offers Crumpler.
Bulk systems present upfront savings, but they place responsibility on the user. “Maintenance requirements are typically higher, warranties on ink-related components are often limited, and changing ink suppliers often means re-profiling materials to keep colors consistent,” shares Check.
Decisions, Decisions
There are options for both DTG and DTF ink delivery systems.
“The choice between bulk and cartridge ink delivery systems should be driven by production volume, operator skill level, environmental controls, and tolerance for maintenance,” concludes Tipre. D
rotection is an important consideration when it comes to offering buyers a well designed, printed, and installed graphic—no matter the application. However, it’s safe to say that some applications are exposed to the elements a bit more than others.
abrasive airborne particles blowing in the wind, the harmful effects of direct sunlight, washes with harsh cleaning chemicals, constant movement, and the stress of regular wear and tear, all end up requiring high-performance durable wrap �ilms,” explains Jay Kroll, director of product education, General Formulations.
“Vehicle graphics get to experience so much more of the world than a static yard sign or window decal. Their interaction with
Above) Avery Dennison Supreme Defense Gloss PPF is a high-grade TPU film, engineered to conform beautifully around complex curves while providing a near invisible protection that enhances the OEM paint finish.
by Melissa Donovan
Today’s vehicle wrap media options—paint protection, color change, or printable �ilms—are engineered to perform on a visual level while also protecting a vehicle’s factory paint. The material composition as well as adhesive technology are prominent factors when determining the speci�ic substrate for the job at hand.
Environmental Factors
Many obstacles are thrown at a vehicle daily—from weather and sunlight to debris from the road.
Hitting some of the main points at a high level, Mattia Casarotto, area manager, EVOLV, says “a vehicle’s exterior is constantly exposed to UV radiation, road debris, chemicals, weather extremes, pollution,
bird droppings, tree sap, and improper washing techniques. Over time, these factors cause paint fading, oxidation, etching, chips, and swirl marks, even on high-end factory �inishes.”
“A vehicle’s factory paint is constantly under attack from a variety of environmental stressors, leading to dullness, fading, and damage,” confesses Brittany Folino, senior product manager, automotive, Avery Dennison Graphics Solutions.
The single largest factor is UV radiation or sunlight. “UV rays break down the chemical bonds in the paint’s clear coat, leading to oxidation—dull and chalky appearance and color fade over time,” continues Folino.
Craig Sykora, research and development director - global application engineering, 3M Company, notes “moisture and road salt— and salt from nearby oceans in some climates—can cause rust and failure of exterior surfaces. On top of that, just driving your car to work or to run errands puts your vehicle at risk from roadway debris like rocks and sand, which can cause damage at roadway speeds.”
Temperature �luctuations are another environmental factor that affects a car’s appearance. “Continuous heating and cooling can cause materials to expand and contract at different rates resulting in stress that can cause cracks to paint and seals,” explains Kaitlyn Porter-Lewis, product manager, Fellers Inc.
How to Protect
Protecting a vehicle’s paint job is a priority. Luckily, it can be done
a number of ways with vehicle wraps, whether through paint protection, color change, or printable �ilms, however the experts agree—paint protection �ilm (PPF) is the product of choice.
“It delivers the ultimate paint protection for your vehicle. Color change vinyl has lower protective qualities, but it does allow for the simplest way to switch up the color of a vehicle,” admits Porter-Lewis.
PPF “creates a physical barrier between the environment and the paint. Unlike traditional wraps that are primarily cosmetic, PPF is engineered speci�ically to absorb impact, resist chemical damage, and block UV exposure, while maintaining a �lawless, premium appearance. This makes it ideal for owners that want both aesthetics and long-term preservation,” explains Casarotto.
Traditional PPF is clear, but color is now an option—operating as color change �ilms that include the bene�its of PPF, referred to as protection wrap �ilms (PWF) or protective color change (PCC) �ilm.
Casarotto believes color PPF is “the most complete solution available today,” as it combines the optical clarity and �inish quality of premium wraps with true paint protection.
3M’s PWF takes colored PPF to the next level by combining the color into the urethane layer—instead of a laminate construction that many other �ilms use. “The �ilm and adhesive combination of PWF gives installers the ability to install the �ilm dry, making installation
faster and easier, while giving the consumer the look of OEM paint,” notes Sykora.
Porter-Lewis refers to color PPF as PCC �ilm, noting that the product offered from Fellers is thermoplastic polyurethane (TPU) and pre-ceramic coated, which allows it stand up to environmental conditions as well offer paint protection.
“PPF is not just a thick vinyl decal; it is an engineered protective shield whose structure—especially when built with TPU—offers multiple advantages like impact absorption, self-healing capabilities, and longterm integrity,” adds Folino.
Material Technicalities
While all �ilm materials are designed to excel in appearance, hitting the right combination between appearance and protection is more challenging to achieve.
According to Sykora, “calendared �ilms do not stretch well and have limitations for installation into recesses such as door cups. Cast �ilms don’t have these challenges.”
“Cast �ilms last longer and look better than calendered �ilms due to the way they’re manufactured. While both types have similar chemical makeups, calendered �ilms are heated, stretched, and run
through rollers to create their �inal form where cast �ilms are mixed with a solvent and coated onto a liner to create the �ilm. It still sees heat as the solvents are �lashed off and the polymers are fused, but the cast �ilm process lacks the physical stretching that is part of the calendering process. This allows the �ilm to stretch farther, but it also maintains the integrity of the individual components that much better,” explains Kroll.
All that being said, “while cast vinyl offers good conformability and appearance for color change or graphics, it was never designed to stop rock chips, scratches, or
abrasion,” notes Casarotto. “From a performance standpoint, urethanebased PPFs deliver the highest level of protection while still achieving a luxury �inish.”
The advantages of urethane or TPU �ilms include self healing, impact absorption, increased surface tension, hydrophobic qualities, and stability against UV light.
In regards to self healing, “the top layer of TPU-based PPF features a specialized self-healing top coat. This unique polymer structure means that when the �ilm sustains light surface scratches or swirl marks, exposure to heat—such as
warm water, a heat gun, or even direct sunlight—causes the polymer chains to re-�low and repair the damage,” explains Folino.
Combating impact absorption, Folino says a premium PPF is usually 7- to 10-mil thick, which is thicker than most color change vinyls at 3- to 4-mil thick. “The elastomeric nature of the TPU core allows it to absorb and dissipate kinetic energy from small high-speed impacts, like rock chips and road debris. When a stone hits the �ilm, the TPU �lexes and rebounds rather than puncturing, preventing damage to the clear coat underneath.”
absorb and dissipate kinetic energy
Porter-Lewis shares that “TPU’s increased surface tension allows stronger adhesion to the �ilm without the need for a prime coat and it reduces adhesive residue when removed. The hydrophobic qualities repel moisture.”
TPU is highly stable against UV light because its chemistry is inherently aliphatic. “This prevents the �ilm from oxidizing, yellowing, or cracking over its long warranted lifespan, which is a common failure point of older, less-advanced protective �ilms,” comments Folino.
Protect with Style
Car owners shouldn’t have to choose between a high-end �inish and long-term durability. Protecting a vehicle’s paint job can be done through paint protection, color change, or printable �ilms. PPF is preferred for many projects, especially as color PPF also known as PWF or PCC continues to grow in popularity. Visit digitaloutput.net to learn more about vehicle wrap media primed for protection. D
#15
#16
by Cassandra Balentine
odern print service providers (PSPs) face challenges from labor shortages to increasing job complexity, shorter runs, disconnected systems, and tighter turnaround times.
“Left unchecked, these pressures slow throughput, increase waste, and erode margins,” cautions Bret Farrah, EVP, Xitron LLC.
Impact varies by size and business model, but Chris Odden, director, digital transformation and integrated solutions, software and strategic solutions, Commercial Industrial Printing Group, Ricoh USA, Inc., believes that all organizations struggle with manual handoffs, inconsistent upstream data, increasing personalization, rising costs, and limited visibility into job status and service levels.
Each print business has its own unique mix of problems to solve. Piet De Pauw, head of marketing, Enfocus, an Esko company, points out that wide format businesses often struggle with accurate scaling, cutter alignment, and
Above) Customer’s Canvas is built to be embedded directly into existing environments. It is designed to serve as the prepress automation engine that bridges the gap between sales channels and backend operations like MIS, ERP, and order management systems.
material nesting, whereas label and packaging printers need MISdriven automation to maintain ef�iciency at high volumes. “That’s why �lexibility is the most important thing to look for in automation software—you can adapt and evolve alongside the industry.”
The right work�low tools help address many of these issues to improve productivity, reduce waste, and increase the bottom line.
Integrating, Automating
The biggest challenge is not lack of technology, according to Alex Bowell, managing director, In�igo, but the gap between what systems should be doing and what happens day to day. “As order volumes increase along with turnaround time expectations, many work�lows are still held together by manual steps, emails, and lastminute checks that don’t scale. When steps aren’t automated or properly connected, production teams spend more time �ixing
problems than producing work, and margins suffer as a result.”
Mariusz Sosnowski, CEO, HiFlow Solutions, adds that manual purchase order intake, invoice matching, and receiving validation is a time sink and error magnet. “Over time, these inef�iciencies compound, increasing costs, tying up working capital, and preventing production teams from operating at the speed and predictability that modern packaging customers expect.”
As a general rule, Marc Raad, president, Signi�icans Automation, feels that the more printing/ �inishing devices and disparate software solutions, the greater the need to simplify work�low processes. “Larger, more complex printing environments demand more agile and sophisticated solutions. However, seamless integration of all of a printer’s production-critical processes has always been the primary challenge. This necessary path to integration can be complex, time consuming, and fraught with errors.”
Hans Sep, product line manager, Fiery, LLC, says print providers know they need automation but face a capabilities gap. “The people who understand print production aren’t programmers. The tools that help require technical skills the industry doesn’t have and can’t hire.”
Technology to the Rescue
Work�low tools are beginning to use arti�icial intelligence (AI) to suggest �ixes, classify incoming jobs, and prioritize queues.
Modern automation software attacks work�low challenges through three interconnected approaches—intelligent integration, data-driven decision making, and end-to-end orchestration, suggests Rick Aberle, founder/CEO, Propago LLC.
In any automation solution, Mike Agness, EVP, Americas, Hybrid Software, says integration is key, “You have to be able to get data from a trusted source in order to program around that data—and build the work�lows.”
Raad agrees. “Integration is key—and AI is becoming one of the major drivers. AI is already disrupting our industry, revolutionizing traditional practices, and introducing new, more efficient solutions. AI offers huge opportunities to optimize
production processes, reduce errors and waste, personalize customer experiences, boost competitiveness, and help employees and management better perform their tasks. AI can read proofs, accept web to print orders, and spot issues with client artwork at the prepress stage.”
AI helps generate data correctly the �irst time. It also builds the logic behind work�lows. “AI can help troubleshoot challenges in the work�low automation solution about required syntax in the coding, but human knowledge is still required to teach any AI engine what needs have to be ful�illed in the work�low,” stresses Agness.
Order Intake Issues
The quality of a �ile and how it is submitted can start a job off on the wrong foot.
In the growing print on demand industry, Servi Pieters, CEO, Viesus AG, points out that anyone can basically create a print product themselves, among various other reasons why printing companies get sub-optimal �iles. “However, the uploaded images often lack in quality—in terms of color and resolution. Usually the printing company needs to cancel the order or go back to the customer for a better �ile. Or they print a low-quality print product, which leads to complaints and non-return customers.”
Dmitry Sevostyanov, CEO, Customer’s Canvas, also sees universal pain points starting at the intake stage. “Inconsistent input data forces operators to waste time manually �ixing �iles. This
friction is often compounded by the approval cycle, where simple changes trigger endless email threads between clients and designers, delaying production and frustrating everyone involved.”
David Graves, CEO, Aleyant, adds that depending on how an AI agent is integrated with work�low software, it can provide context and clarity to the results of a pre�light report—such as font embedding, resolution, bleed requirements—and change a lot of technical terms to plain language depending on the level of the user.
Modern tools like Caldera’s PrimeCenter prepress automation hub help to optimize, automate, and standardize �ile preparation before printing and cutting, shares Sebastien Hanssens, VP of marketing, Caldera.
Onyx Graphics, Inc. integrates directly with QuickBooks Online, automating the invoice and
payment work�low between order management and accounting software. “We integrate directly with ONYX Thrive, allowing users to submit print-ready �iles directly from the order to the RIP,” shares Calvin Tuttle, product manager, ONYX Align, Onyx.
Canon’s PRISMA solutions integrate MIS/ERP, data composition, print, and �inishing while providing real-time production insights.
“Emerging capabilities such as AI-assisted decision making and predictive analytics further reduce operator dependency and improve production consistency,” offers Kevin Roman, director of professional services, Production Print Pro Services, Canon U.S.A., Inc.
Time to Evolve
Within three to �ive years, Sep predicts work�low automation won’t be a competitive advantage—it will be table stakes. “Print providers without AI-assisted routing, real-time
enterprise connectivity, and automated quality control struggle to compete on turnaround, pricing, or reliability. The question isn’t
whether to automate. It’s whether to lead the transition or be forced into it by competitive pressure.” D
7
#7
n the last few months, there have been multiple introductions in the three-meter roll-to-roll (R2R) printer space. Whether it be three, 3.2, 3.4, or 3.5 meters in width, these devices offer not only productivity, but high print quality, all past 100 inches.
Narrowing In
Three-meter R2R devices are popular right now for a number of reasons. Key
by Digital Outpu t Sta
factors include the ability to print on various substrates, which consequently means the capability to produce multiple applications on one device; consolidating production from several printers to one; and yielding quality prints at high levels of productivity.
“The momentum around three-meter R2R platforms is driven by market demand and economic forces for lower
cost output through volume printing. Print providers consolidate equipment footprints while expanding application versatility. A 3.2-meter platform supports a range of substrates without the cost and space of �ive-meter systems or multiple printers like a �latbed and R2R,” says Adam Tourville, channel manager, Fluid Color.
Above) HP’s R2R printers include the 3.2-meter HP Latex FS50/60 Printer Series.
Quality and consistency are addressed. “Retailers, brands, and event producers demand rich color, smooth gradients, and �lawless surfaces, which this width supports well. At the same time, many print shops want to consolidate production on fewer, more capable devices. A high-performance system in the three-meter class provides versatility for a wide application mix while maintaining premium output quality,” shares Erik Norman, president, swissQprint America.
Demand for three-meter R2R printers derives from print service providers (PSPs) looking for greater control over print quality, notes Gabriel Crumpler, TA segment specialist, Mimaki USA, Inc. “Prompting many companies that previously outsourced printing overseas to bring production in house. This shift helps reduce production costs, mitigate risks associated with tariffs, and gain tighter control over turnaround times and quality standards.”
“Labor supply is a big challenge in the print industry speci�ically, and manufacturing broadly. Highspeed unattended R2R printing delivers the highest productivity at the lowest labor required,” explains Ted Pierpont, national sales manager for large format, Durst Image Technology US.
Other reasons PSPs bring wide format work in house—which in�luences the demand for threemeter devices—include falling hardware and ink costs, combined with higher usable speeds. This is particularly true for midsize shops looking to take on time
sensitive or brand critical jobs,” suggests Mark Crawford, business and product development manager, Vanguard Digital Printing Systems, a Durst Group Co.
business and product
“Many PSPs see the need to while adding burst capacity and three-meter offerings deliver a
“Many PSPs see the need to expand form factor and capacity while adding burst capacity and application range. The most recent three-meter offerings deliver a solid solution to the PSP’s need of serving an existing customer base while also enabling them to attract new customers,” adds Thomas Giglio, HP Latex segment manager, North America, HP Inc.
Looking at things from an external perspective, “market trends like retail refresh cycles, experiential branding, and short-run customization drive demand for larger graphics and faster turnaround,” which plays into increased interest for three-meter devices, shares Katsuhiro Matsufuji, VP, marketing strategy unit, Canon U.S.A., Inc.
Koen Steert, head of product management and applications, Agfa, believes “interest is largely driven by next-generation models from established players in the market that are introducing new features such as improved automation, rather than entirely new technologies.”
Expanding Applications
Applications also fuel adoption of three-meter printers. According to Tourville, the versatility of this platform’s width makes it “invaluable for shops expanding their service range.”
Norman lists retail graphics, backlits, soft signage, and interior décor as key application drivers, with window �ilms, self-adhesive vinyl, and premium event graph- range of large format display and
vinyl, and premium event graphics also signi�icantly contributing. “Print shops want a single device that delivers exceptional image quality across all of these applications. The three-meter format allows them to cover typical campaign sizes ef�iciently.”
“PSPs use these printers for oversize work, but there is a shift into décor and event support, while a constant presence in �leet/vehicle graphics is also required,” notes Giglio.
With the need to remain competitive on pricing and turnaround times, PSPs are motivated to push what Matsufuji refers to as “bread and butter applications” like banners, wallcoverings, and wraps onto three-meter units. Furthermore, as some R2R systems can be upgraded to hybrid devices, he says “this opens the door to rigid applications like point of purchase (POP) displays, yard signs, and packaging.”
Other applications driving adoption, according to Crumpler, include banners, posters, indoor and outdoor graphics, and silicone edge graphic (SEG) fabric printing.
“These versatile systems enable high-quality production across a range of large format display and textile applications.”
“Within the industry, soft signage and fabric-based backlits have moved �irmly into the mainstream, with brands standardizing on 3.2-meter frames, SEG light boxes, and tension systems for retail, events, and corporate environments,” notes Crawford.
Bands of Ink
Printers in the three-meter width range pop up in every ink category from aqueous to latex and UV.
According to Crumpler, aqueous printers are well suited for printing on polyester materials and are often chosen for their more environmentally friendly ink formulations. They support highquality output for both indoor and outdoor applications, making them a popular option for textile and fabric-based graphics.
Under the category of aqueous falls latex. For wider format R2R devices that utilize latex inks, it’s
1) Canon’s Colorado XL-series includes a 3.4-meter UVgel printer that incorporates proprietary technology, Full-Beam Curing, to deliver uniform UV exposure across the entire width to create wrinkle-free, high-density prints.
a perfect marriage of what the ink can achieve and the three-meter width. “Wall décor demands high quality in many cases with white ink and the vehicle segment demands �lexibility and conformability. The thin �ilm thickness of HP Latex inks meets both requirements,” notes Giglio.
UV LED is highly favored in R2R production. “These inks deliver excellent adhesion across a range of substrates and high color density for demanding applications such as backlits and retail displays. When paired with a controlled UV LED curing system the ink and hardware form a consistent, reliable production environment that supports long print runs and repeat jobs with stable results,” says Norman.
Steert maintains that UV is a dominant choice in most instances because “it offers the broadest media compatibility and application scope. This technology is used on
everything from self-adhesive vinyls to textiles and �lexible �ilms, making it ideal for PSPs serving varied applications.”
“UV inks deliver durability and fade resistance suf�icient for outdoor and long-term installations at quality approaching lithography. Fine text and details for closely viewed marketing pieces is achievable on the same platform that produces stadium banners and fence mesh. The breadth and volume of product that can be pro�itably made by a single worker is incredible,” marvels Pierpont.
There are ef�iciency gains related to UV LED. “LED curing reduces heat and energy consumption, allowing shops to run heat-sensitive materials more con�idently and operate more ef�iciently, while still providing the durability needed for most indoor and outdoor applications, often without lamination,” explains Crawford.
“UV’s ability to print on diverse substrates without heat distortion or extended drying times makes it
attractive for high-speed, high-quality production environments. Because they are non-evaporative, UV ink printers typically have a lower running cost than alternative technologies,” notes Matsufuji.
Where is solvent in all of this?
“Solvent continues to fade from new three-meter investments due to longer turnaround times and environmental concerns,” says Crawford.
Popular Features
Three-meter wide devices can be equipped with effective features.
“Dual roll printing, loading two narrower rolls side by side on the same spindle, can be a signi�icant productivity booster. On certain printers, dual roll mode allows simultaneous output on two rolls during each carriage pass. This reduces wasted travel time and increases square feet per hour ef�iciency without compromising quality,” explains Matsufuji.
Dual roll printing is essential, points out Giglio, because many substrates are not available in the 3.2-meter form. “Case in point, self-adhesive vinyl is most popular in 54- or 60-inch rolls, driven by �inishing and installation practices where equipment and capability is less than two meters.”
Pierpont notes that certain media like wallcoverings are commonly printed at 64 inches
or less, making dual roll printing advantageous here as well.
“Dual roll printing is increasingly popular for retail graphics, POP, and short-run campaigns. It doubles output without increasing footprint. In a high-volume shop dual roll is a must and multiple jobs can be printed together on the same rolls. This helps lower costs of production time and labor,” adds Tourville.
Three-meter systems may include automated cassette roll loading systems, vacuum handling for precise tension and alignment, and intelligent tension control, which reduce setup time and minimize waste. “These improvements support consistent output quality, shorten changeover times, and give operators con�idence when handling complex work�lows such as double-sided or multi-layer printing,” explains Norman.
Other advances that make threemeter R2R printers more appealing include “inline cutting features in both x and y directions, supporting more ef�icient �inishing work�lows; as well as smart solutions for mesh printing, enabling liner-free production with integrated ink collection systems to prevent contamination and waste,” adds Steert.
Three-Meter Spotlight
PSPs �ind wide format roll printers in the three-meter width range attractive for a number of reasons. Visit digitaloutput.net and read a web-exclusive article on roadblocks to implementing these devices in house as well as the newest available models. D
