What Is The Difference Between Monomeric, Polymeric And Cast Vinyl?

Do you know the difference between monomeric, polymeric and cast vinyl? This guide explains how they differ and how that affects performance.

What is the difference between monomeric, polymeric and cast vinyl?

You can tell a lot from the names given to the two types of calendered vinyl. “Mono-” means one, “poly-” means many and “-meric” means body or unit. Monomeric and polymeric describe the type of plasticiser used to create the finished vinyl. Cast vinyl is not calendered, although it uses the same type of plasticiser as polymeric vinyl. Its different manufacturing process produces a more stable and durable material. Calendered vinyl is manufactured using rollers, which place more stress on the material and make it less dimensionally stable.

What is vinyl?

Vinyl is made from polyvinyl chloride (PVC), a synthetic plastic derived from chlorine and ethylene. Processing these ingredients produces PVC resin.

How is calendered vinyl made?

The ingredients are melted and, as they cool, the molten PVC is passed through calendering rollers to create the required width, thickness and surface finish.

Calendered vinyl costs less to manufacture than cast vinyl. It requires no solvent or casting mould and uses less energy. As a result, it is less resilient than cast vinyl, although it is suitable for many applications.

How is cast vinyl made?

Cast vinyl is made by combining PVC resin, plasticiser and any required colourant with a solvent to form a paint-like substance. The mould film determines whether the finished vinyl has a matt, semi-gloss or gloss finish.

The vinyl is then dried and cured at a high temperature to form a flexible film. The production temperature is higher than the temperatures encountered during application, helping the material withstand distortion and heat without degrading or warping.

What is a plasticiser?

A plasticiser is added to PVC to make it flexible and less brittle. Without plasticisers, PVC is hard and brittle and may shatter if bent or flexed.

Monomeric vinyl uses smaller-molecule plasticisers. These can migrate more readily and may have a greater effect on adhesives.

Polymeric vinyl uses longer-chain plasticisers that bind more strongly into the vinyl. This reduces migration and their effect on adhesives.

Monomeric vinyl

Monomeric vinyl is popular because it costs less and suits flat surfaces, meeting most signage needs. It typically has an outdoor life of around 2–5 years and can shrink, so it is best for indoor or flat applications. It can also be used outdoors for short-term applications.

Why choose monomeric vinyl?

• Ideal for standard, flat applications
• Lower cost
• Short-to-medium service life, suitable for many uses

Why decide against monomeric vinyl?

• Not suitable for uneven surfaces
• Can shrink

Polymeric vinyl

Polymeric vinyl is suitable for indoor and outdoor applications, including mild curves. It typically has a medium-term outdoor life of around 5–7 years. It is more resistant to shrinkage than monomeric vinyl and is more stable.

Why choose polymeric vinyl?

• Longer life span
• Less shrinkage
• Suitable for flat and slightly curved applications

Why decide against polymeric vinyl?

• Can cost more than monomeric vinyl

The next time you choose a calendered film, consider the differences:

Cast vinyl

Cast vinyl is a premium, high-quality vinyl with a lifespan of around 8–10 years. It is soft, thin and flexible, making it suitable for vehicle wrapping, for example. Unlike calendered films, cast vinyl does not shrink or pull back to its original form when exposed to heat, such as from a heat gun.

Why choose cast vinyl?

• Longer life span
• Conforms to severe recesses
• Soft, flexible and thin

Why decide against cast vinyl?

• Higher cost; it may be worth it when durability and conformity are priorities

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