News

In the world of wrapping, many installers experience issues with film failure, shrinkage, or extra difficult applications even when they did all the right steps in terms of prep, install and post install.  One key factor that is often overlooked is a deep understanding of how the material is made. Learning about how the film is made helps you appreciate how much tension is built into the film from the manufacturing process as well as where it wants to shrink during the install.  In addition, understanding the complexity and how much it costs to make the film gives you a better appreciation of the hurdles a manufacturer has to jump over in order to provide you with a great product that is consistent day in and out.  

Calibrating the Film
When you go to make glass or form the film into a deep recessed area, do you have to pull or push really hard? If you do, you probably didn’t use the Zero Stretch technique.  All film comes “pre-stretched” from the factory.  The range of pre-stretch runs from 2% up to 20%!  Leaving this tension in the film while wrapping can make the process much harder  Plus it leaves unwanted tension on the surface which can lead to failures down the line.   A critical technique to prevent this is the "Zero Stretch" method, invented and taught by The Wrap Institute. This technique uses slow heat to “re-calibrate” the material’s tension before the manufacturing process back to zero.  This can be done before or during the install.  Doing this helps ensure that the film performs better than expected during application, makes the wrapping process much easier and leaves much less tension on the surface.  It only takes a few seconds to do, yet it's a powerful step that can make a huge difference.

Cast vs. Calendar Film
Do you know why calendar films shrink more than cast films? The difference lies in the way they’re manufactured. Cast films are made by pouring liquid resin onto a casting sheet much like pancakes on a griddle., This makes the film more stable, durable and less prone to shrinking. Calendar films, on the other hand, start off as a solid in the form of a tube that comes out of an extruder.  The makeup is similar to pizza dough.  This tube is carried between spinning calendar drums that flatten it into a thin sheet.  Because calendar film starts off as a solid, it's more prone to shrinking over time. Understanding this distinction helps you select the right material for the job and avoiding common issues like shrinking or edge failure.  A good rule of thumb is: Calendar for flat, cast for curves.

Loving the liner!
We all love that most of today’s wrapping films slide easily across the surface and bubbles disappear with a press of a finger.  Did you know that these key features of the adhesive actually come from the liner during the manufacturing process?  The liner has tiny topographical features that dictate the structure of the air egress channels as well as how slidable the film is. Some companies produce their liners in-house, but most companies purchase them from specialized companies like Mondi. 

The film manufacturers request certain performance and aesthetic features.  The liner manufacturer then tweaks the liner to meet those needs.  Each tweak to the depth and structure of the channels changes the tack, flow of air and maintaining a paint like finish for the long term.  It’s complicated yet once dialed in the flow of install and finish can be amazing. Kind of sounds like choosing your coffee at Starbucks, right?

To explore more on this topic, check out these informative videos on The Wrap Institute:

1. TWI Fundamentals: Making Calendar Film

2. TWI Exclusive: Training The Wrap Tiger - Arlon Headquarters Plant Tour and Workshop

3. TWI Interview: 27-Minutes with Michael Althoff - Owner of Yellotools

4. TWI Business: Green = Green Orafol - Manufacturing with Josh Culverhouse

5. Mondi AirXliner
   
   As always, The Wrap Institute is here to help you elevate your skills. Keep seeking new knowledge, push your boundaries, and Never Stop Learning.

Marcos Schott - Certified Car Wrapper and TWI CCO