When it comes to transforming the look of your car with a vinyl wrap, understanding the different types of wrap materials is crucial. Vinyl wraps generally come in two main types: cast films and calendared films.
If you’re not familiar with the differences, you might wonder why some wraps are more expensive than others and if the extra cost is really worth it. Let's dive into why cast films are the only choice for high-quality automotive wraps and when calendared films might still work for certain applications.
What Are the Types of Vinyl Construction?
Before diving into the specifics of cast and calendared films, let’s first look at how vinyl wraps are made. Both types of films are essentially sheets of vinyl that can be applied to various surfaces. The differences come down to how they are manufactured, which affects their flexibility, durability, and appearance.
Cast Films: These are made by casting a liquid mixture onto a casting sheet, which is then heated to evaporate solvents, leaving behind a thin, flexible film. This process creates a durable, long-lasting vinyl wrap that can conform to the curves of a vehicle like a second skin.
Calendared Films: These are manufactured by heating and stretching thicker sheets of vinyl through rollers, which results in a thicker, less flexible film. While calendared films have their uses, they typically don’t offer the same performance or finish as cast films, and can't conform to the complex curves of an entire body panel.
Understanding the Differences Between Cast and Calendared Vinyl Wrap
Flexibility and Conformability
One of the biggest advantages of cast films is their flexibility. Because they’re made from a liquid, there's no tension in the film and they want to stretch. This means they're better at conforming to complex curves, sharp edges, and deep channels on a vehicle’s surface. Think about wrapping a sports car with a lot of intricate body lines—cast films will contour to every curve, giving you a flawless finish.
For example, we've wrapped several Porsche GT3's using high-quality cast films. The complex curves of the car’s fenders and rear were no problem for the wrap, which looked smooth and seamless. If I had used a calendared film, there’s no way it would have conformed to those complex curves.
On the other hand, calendared films are stretched out to make the film, so rather than wanting to stretch, they want to shrink. They can be used for flat surfaces or simple curves, but if you’re aiming for a wrap that looks as close to a paint job as possible, cast films are the way to go.
Durability and Longevity
Another area where cast films shine is durability. Since they’re less prone to shrinking, cracking, and fading, they last longer than calendared films. If you live in a place with harsh weather conditions—extreme heat, cold, or even heavy rain—a cast film will hold up better over time.
Cast films are expected last at least 5-7 years, depending on maintenance and exposure to the elements. We've seen plenty of wraps over 10 years old that are still in great condition! Calendared films, on the other hand, usually last a couple of years before showing signs of wear and tear. We've seen our fair share of calendared films that didn't even make it a full year before cracking and shrinking! If you’re investing in a wrap, you probably want it to stay looking fresh for as long as possible, and that's only possible with cast films.
Appearance and Finish Quality
For those who want the look of a high-end paint job without the cost, cast films are the only choice. They offer a smoother, more consistent finish and come in a variety of finishes—gloss, matte, satin, metallic, chrome, you name it. Cast films also better mimic the glossy qualities of real paint, making them an ideal choice for any car owner who wants a premium appearance.
Calendared films, while available in similar colors and finishes, often have a more textured appearance, and may not look as smooth when applied. They are better suited for applications where appearance is not the primary concern, such as temporary wraps or commercial signage.
Price Differences
Cast films typically come with a higher price tag due to the more complex manufacturing process and the overall higher-quality of the material. However, this investment pays off in the long run. The durability and superior appearance of cast films mean that you won’t have to replace or touch up your wrap as frequently.
We've had a few clients who initially scrutinize the cost of a cast film wrap, opting for cheaper calendared graphics instead. A year later, they came back because the calendared film had started to shrink and crack, especially around the edges. They ended up spending more in the long run by having to redo the wrap with a cast film.
While the extra cost for a cast film might seem significant upfront, it can actually save you money over time by reducing the need for frequent replacements.
Common Applications for Cast vs. Calendared Films
When to Choose Cast Films
Full Vehicle Wraps: If you’re wrapping your entire car, cast films are the best choice. Their flexibility allows them to conform to complex shapes, providing a flawless finish.
Long-Term Applications: If you plan on keeping the wrap for several years, the extra durability of cast films is worth the investment.
Greater Flexibility: Both in how the film conforms and how it can be used. Cast films are capable of covering much more complex curves without lifting, peeling, or shrinking.
When to Choose Calendared Films
Simple Decals or Graphics: For flat surfaces like doors, hoods, roofs, or windows, calendared films can work just fine. They’re often used for commercial fleet graphics where cost is a bigger concern.
Temporary Wraps: If you need a graphic for a short-term event or promotion, a calendared film can be a cost-effective solution.
Budget-Friendly Projects: For those looking to add a bit of flair without breaking the bank, calendared films can still be a viable option, as long as the expectations are clear.
The Pros and Cons of Cast and Calendared Films
Pros of Cast Films
Superior Flexibility and Durability: Ideal for complex surfaces and long-lasting wraps.
High-Quality Appearance: Mimics the look of paint with a smooth finish.
Greater Variety of Colors and Finishes: Available in more color options, including unique finishes like chrome or pearlescent.
Cons of Cast Films
Higher Cost: May not fit every budget.
Requires Professional Installation: Due to the thin material and flexibility, DIY installation can be tricky.
Pros of Calendared Films
Lower Cost: A budget-friendly option for basic projects.
Great for Promotional Graphics: When running a short term campaign or advertising for an upcoming event, calendared decals are more than capable.
Cons of Calendared Films
Less Flexible: Not suitable for complex curves or full vehicle wraps.
Shorter Lifespan: Prone to shrinking and cracking over time.
Appearance May Be Inferior: Doesn’t have the same smooth, paint-like finish as cast films.
Key Considerations When Choosing a Vinyl Wrap
Project Purpose and Duration
Consider how long you plan to keep the wrap on your vehicle. If it’s a long-term investment, a cast film is the better choice. For short-term projects, like promotional vehicle graphics, a calendared film may suffice.
Budget Constraints
While cast films cost more, they’re worth the extra expense if you want a premium look and longevity. If you’re on a tighter budget, calendared films can still be a good option for simpler or temporary wraps.
The main thing to consider is how the wrap will be used, and what surface it's installed on. Some situations may still require cast vinyl, depending on the scope of the project.
Outdoor Exposure
When it comes to dealing with the elements, cast vinyl is the clear winner. Cast films hold up to harsh weather and UV from the sun much better than calendared films.
If you're looking for graphics for your storefront, even though calendared vinyl can do the trick most times, if you're worried about longevity, especially for surfaces that see a lot of sun exposure, cast vinyl may still be the better choice.
Conclusion
When it comes to vinyl wraps, cast films offer a superior combination of flexibility, durability, and appearance, making them the best choice for most automotive applications. We exclusively use cast films for any full vehicle wrap, whether it's a color change or a full print wrap. While calendared films have their place, especially for budget-conscious and simpler projects, they simply can’t match the premium quality of cast films.
If you’re thinking about wrapping your car, don’t hesitate to get in touch with us! We can help you choose the right film for your specific needs and ensure your vehicle gets the best possible finish.