Wrapping: The Evolution(s) - Part 1

By Paul Roba

n last month’s edition of WrapFam Unleashed, I presented the “revolutions” that occurred in the vehicle wrapping industry. These significant changes to the products and processes used to create wraps were instrumental in the explosive success of the wrap segments.

The revolutionary transformational changes previously discussed were:

• Printing technology, the digital age,

• Adhesive changes, design of repositionable adhesives,

• Liner changes, the introduction of air egress patterns,

• PVC face film engineering, creation of dual cast products.

Many would say that I missed many other changes that transformed the vehicle wrap industry. It is true, but in my opinion, these other changes were “evolutionary” not “revolutionary”.

What is a definition of “evolution”, from the Merriam-Webster online dictionary?

Evolution: a process of continuous change from a lower, simpler, or worse to a higher, more complex, or better state

The vehicle wrap industry has undergone many important evolutionary changes, where improvements have been made in various areas.

The progress areas include the following sections:

• Product engineering

• Converting technologies

• Training

• Application Process

• Tools

• Fellowship

In this article, I focus on the evolution seen in product engineering and converting technologies. Part 2 will look at training, application processes, tools, and fellowship.

Product Engineering

The components used for wrapping materials include the face film (for print or color change), protective laminates, adhesives, and liners. Each of these components has evolved as manufacturers identify potential improvements from feedback from industry professionals, product & manufacturing engineers, and general market trends.

The typical face film has historically been made of cast PVC, and it has evolved to become more flexible & thinner, have better printability, different finishes & textures, and extended durability. Calendered PVC films have also improved in their formulation and engineering as well, creating a viable alternative to cast films in many instances.

Additionally, face films have been migrating towards more environmentally conscious products. Non-PVC products have emerged and continue to improve and perform similarly, or better to industry standards. Extruded thermoplastic urethane (TPU) has been an industry staple, but Orafol has launched Orafol 3981 RA, the first cast digitally printable TPU product driving change in how materials can be manufactured. In addition to the increase in printable TPU films, color change films in

TPU formulations are gaining in popularity as they provide a tough/durable high gloss and exceptionally paint-like finish.

All the face evolutions have been well received in the industry, and have been made even better by the evolution of adhesive performance. Traditionally, many adhesives had been designed to provide quick stick capabilities, but most manufacturers have modified their adhesive polymer technology to provide differing degrees of repositioning and removability characteristics. The adhesives can be complemented by differing design methodologies to slide or reposition the face film.

Not to be forgotten, the liner/backer/carrier sheet of the wrap products provides protection, handleability, air egress (for print and color change products), or glasslike finishes(for protective laminates). The original air egress design of the liners was limited to diamonds or hex patterns, but technology has driven the evolution of square, random bubble patterns, and other patterns to complement bubble-free applications. Patterns have evolved in reducing their size as well, creating less of a pattern show-through for the super conformable films of the industry.

Converting Technologies

When considering converting wrap products we focus on printing, cutting, and laminating for print wraps. Each of these areas of converting has evolved over the years to create graphics faster and with higher quality.

Digital printing has changed by adding new technologies like latex, aqueous resin, flexible UV, and UV gel technologies to complement traditional solvent & eco-solvent-based print technologies. Each evolved over time and utilized the basic chemistry of a carrier, pigments, colorfast inhibitors, stabilizers, and resins. I am not going to get into the complexities of each technology, just a basic presentation of how they are different.

Technologies have changed how to carry and cure the inks. Originally a carrier or oilbased solvent delivered the inks to the substrate, and heat plus air circulation cured them.

As resin-based or latex inks evolved the carriers changed to aqueous-based systems reducing volatile organic compounds but still required heat to set/cure the inks. This made it easier for print service providers to create graphics in a short time without waiting for solvents to be evacuated from graphics. The change to a water-based carrier also helped to reduce solventbased shrinkage seen in some films.

Early latex ink tech required extreme heat to cure and set the inks, so you could see shrinkage from the high heat, or it was difficult to print on some delicate substrates. Progress here has engineered the inks and [printers to require lower temperatures improving the overall latex print process. This technology also has had an impact on the environment, as VOCs are no longer released into the environment.

UV ink technology has improved as the printers, cure technology, and inks have been engineered to provide greater flexibility, smoother print output, matte & gloss ink finishes, and performance needed for vehicle wraps. These inks originally were cured by very bright ultraviolet light which generated a great deal of heat. New formulations of inks and curing technology have made it possible to cure the inks under LED cool bulbs, eliminating issues around materials being damaged by intense heat and providing greater flexibility and same-day lamination like water-based inks. a vehicle, square cutting for full wrap sides, or contour cutting for partial wraps, or overlays. Manufacturers of cutting equipment have implemented easyto-use software to achieve the finished cuts and intricate designs one needs. In addition, as engineering designs of the equipment improve, one can set it up easily, process material faster and obtain greater accuracy.

Although I tout the evolution of latex/resin and UV inks, it should be recognized that some current ecosolvent-based inks have been improved. Although they still require time, air circulation and heat to cure the inks, they have evolved into systems that can be used for same-day creation of graphics.

In regards to laminating, many equipment manufacturers have simplified the process, allowing for quick setup, and turnaround of protected graphics. By utilizing improved technology; web paths are less complicated, consistent pressure allows easy alignment and little drift, easy to set knives make for inline product trimming, and equipment design allows quick loading and unloading of materials.

Many wraps do not require extensive cutting, but finishing and cutting of materials has evolved so print service providers can supply the installer a product in the form they need. This may include panel cutting for specific areas of

Although some may argue that some of these evolutions could be considered revolutionary, I look back to the definition from the Merriam-Webster online dictionary regarding evolution. It is “a process of continuous change from a lower, simpler, or worse to a higher, more complex, or better state” and I believe these areas show incremental steps, possibly with some extraordinary individual developments behind them.

Until next time!

Paul Roba

Paul Roba is a graphics and wrap industry veteran of over 35 years. He was involved with the early design, rollout, and training programs of wrap films.