SpecialFocus Plastic-Based Rigid Substrates for Fabricating Signs,Plastics in Heavy Idustrial Construction Displays

Fabrication in Signs/Merchandising

by Brandon Wyatt

hen the original paper-faced foam board was introduced in be formed easily into 1959, it marked a turning point in the graphic display industry. just about any shape WNo longer were graphic designers involved in the creation of imaginable using wood visual merchandising displays and signage limited to the fabrication and and foam board fabrica- usage constraints of flimsy cardboard or heavy chipboard. tion techniques as well as heat forming tech- The original paper-faced foam board consisted of white extruded niques. This PVC board polystyrene foam bonded between various high-quality papers that fea- provides superior dent tured a smooth surface for decorating — a unique product composition and scratch resistance. that offered rigidity, light weight, warp resistance and cutting ease in a graphic display substrate. With the introduction of paper-faced foam Aluminum com- board, graphic designers could create lightweight yet sturdy displays posite material (ACM) and signs that could be decorated with mounted images, screen printed was introduced to the or painted, and finished with knife-cutting and die-cutting/punching graphic display market techniques. The original paper-faced foam board also uniquely allowed in North America in the embossing techniques to create three-dimensional effects in displays mid-1990s. This lighter and signage. version of the origi- nal ACM developed for Gatorfoam®, the original heavy-duty foam board by 3A With the wide acceptance of paper-faced foam board in the graphic architectural applica- Composites USA, consists of extruded polystyrene foam display industry, paper-faced foam board product line extensions soon with wood-fiber veneer facers. It offers an excellent repu- tions is comprised of two were developed to meet specific customer needs, including: black foam tation for digital printing and screen printing. This rigid pre-painted sheets of boards for dramatic display designs; foam boards with acid-free paper substrate resists dents and scratches and routes cleanly .012" aluminum with a with ease. liners for archival mounting projects; heat-activated foam boards for solid polyethylene core. quick, damage-free mounting; and recovery foam boards that retain their This ACM is designed to be digitally printed and provides a superior surface original shape after die-cutting. that protects mounted digital and screen-printed graphics. It offers excellent Then came plastics durability in outdoor applications and can be routed and returned to add A wide range of innovative plastic-based rigid substrates has followed dimensional shapes or roll-formed to deliver sweeping curves in designs. paper-faced foam boards into the market to meet graphic designers’ Today’s plastic-based rigid substrates include: paper-faced foam boards, continually evolving needs. Designers requested rigid substrates that fluted polypropylene boards, expanded PVC boards, extruded polystyrene could stand up to long-term indoor display as well as outdoor display. foam with no facers, heavy-duty foam boards with wood-fiber veneer facers, They requested rigid substrates that could be formed easily into unique heavy-duty foam boards with polystyrene cap sheets and aluminum compos- shapes. And they requested rigid substrates that could be direct digitally ite materials with a solid polyethylene core. printed with the latest technologically advanced equipment. Among the most notable plastic-based rigid substrates that followed Selection guide paper-faced foam boards into the graphic display market was the first There are so many plastic-based rigid substrates available today that it can heavy-duty foam board featuring wood-fiber veneer facers introduced become a confusing process for plastics distributors to recommend graphic in 1976. This heavy-duty foam board was introduced to meet graphic display boards to customers creating signs and displays. Recommended rigid designers’ needs for a foam-centered board with high structural strength, substrates not only must meet fabrication and decorating requirements but durability and outdoor applicability. also varied exhibit length requirements as well as project budgets. Another notable product launch was the industry’s leading polyvinyl To make choosing a graphic display board easier, I would like to offer chloride (PVC) board, which was introduced in North America in the early the following descriptions of a wide range of popular plastic-based rigid 1980s. This PVC board — comprised of moderately expanded closed- substrates with some corresponding fabrication and decorating techniques. cell PVC in a homogeneous sheet with a low-gloss matte finish — can Rigid substrates are listed below from lowest price points to highest:

20 February/March 2013 The IAPD Magazine www.iapd.org Fluted polypropylene Heavy-duty foam boards with polystyrene cap sheets. This heavy-duty boards designed spe- foam board is lightweight and water-resistant. It features smooth, high- cifically for graphic impact facers that resist warping. Vinyl graphics applied to this board are displays. These cost- repositionable. This board may be decorated with digital printing, screen effective rigid sub- printing and painting techniques (with non-solvent paints recommended). strates are extremely Heavy-duty foam boards with polystyrene cap sheets are a good choice for lightweight yet rigid. medium-term displays, exhibits/kiosks and interior signage. They are color consis- Aluminum composite materials with a solid polyethylene core. These tent and offer good extremely flat materials may be digitally printed and offer a superior adhesion for vinyl surface finish for adhering expensive digital and screen-printed graph- graphics. Fluted poly- ics. These materials provide excellent durability in outdoor applications. propylene substrates Aluminum composite materials (ACMs) are one-half the weight of solid also may be direct aluminum sheets. ACMs are a good choice for creating long-term displays, digitally printed and exhibits/kiosks, framing, interior/exterior signage and structural signage. screen printed. Fluted polypropylene boards

are a good choice for ® Brandon Wyatt is market manager, Graphic Display, at Statesville, N.C.-based 3A Sintra , the industry’s leading PVC board by 3A Composites Composites USA. For more information, contact: 3A Composites USA, Inc., 3480 medium-term dis- USA, is comprised of moderately expanded closed-cell Taylorsville Highway, Statesville, NC 28625 USA; (704) 872-8974, fax: (704) 878- polyvinyl chloride in a homogeneous sheet with a low-gloss plays, exhibits/kiosks 2708; email: [email protected]. Visit www.graphicdisplayusa.com and and interior signage matte finish. It can be formed easily into just about any shape imaginable using wood and foam board fabrication “Graphic Display USA” on Facebook at http://on.fb.me/V1Cpdq. as well as short-term techniques as well as heat forming techniques. ® Gatorfoam, Sintra and Fome-Cor are registered trademarks of 3A Composites exterior signage. USA. Paper-faced foam boards. As described above, these rigid substrates — which are comprised of extruded polystyrene foam bonded between various high-quality papers — are extremely lightweight yet durable. The original paper-faced foam board can be die-cut, creating a compressed edge that stays closed; and it uniquely may be embossed to create three- dimensional effects. Paper-faced foam boards are a good choice for short- term displays, exhibits/kiosks and interior signage as well as for long-term framing applications. Expanded PVC boards. Substrates comprised of expanded PVC are light- weight yet rigid and durable and offer dent and scratch resistance. Expanded PVC boards are easy to machine. They are heat formable and chemical resistant. They may be digitally direct printed, screen printed and painted. Vinyl decorations are repositionable. Expanded PVC boards are a good choice for medium-term displays, exhibits/kiosks, interior signage and exterior signage as well for long-term framing applications. Extruded polystyrene foam without facers. Extruded polystyrene foam is perfect for creating signs, displays and dramatic in-store lettering. It is lightweight yet durable and easy to cut and form. It’s easy to paint — with non-solvent based paints recommended — and cut. Mounted graphics may be applied. Extruded polystyrene foam without facers is a good choice for creating medium-term displays, exhibits/kiosks and inte- rior/exterior signage. Heavy-duty foam boards with wood-fiber veneer facers. The original heavy-duty foam board offers an excellent repu- tation for digital printing and screen printing. This rigid substrate resists dents and scratches and routes cleanly with ease. Heavy-duty foam boards with wood-fiber Fome-Cor®, the original paper-faced foam board by 3A veneer facers are a good Composites USA, consists of extruded polystyrene foam choice for medium-term bonded between various high-quality papers that feature displays, exhibits/kiosks a smooth surface for decorating. Fome-Cor board can be die-cut, creating a compressed edge that stays closed; and, and interior/exterior sig- it uniquely may be embossed to create three-dimensional nage as well as long-term effects. framing applications. www.iapd.org February/March 2013 The IAPD Magazine 21