Resin Printing vs. Inkjet printing

What you should know before you buy

The first question anyone in the sign industry asks about full color output is "How long will it last outdoors"? As you will see from this comparison, longevity is not the most important factor when purchasing a full color output device.

As in all purchase decisions, the first step is to define your market. Do you produce mostly automotive graphics? If so, what sizes do you anticipate producing? Do you have a broad spectrum (trade show graphics, retail graphics, interior signage, etc.)? Later on you will see a matrix which will indicate the best machine for your market.

Ease of production and quality are very important when producing full color graphics. Think about the entire picture before making your decision.

One final comment. We do not sell Gerber equipment (described herein), and our comments are based on information provided by Gerber and Gerber users.

Resin Technology:

Resin Printing uses thin films of colored resin, which are heat applied to a substrate. There are three major producers of thermal resin printers: Gerber, Summa, and Roland. Each uses slightly different technology to accomplish this end,

Advantages: Prints on smooth untreated flexible substrates.

Bright, vibrant colors

Long UV life (3-5 years outdoors)

Can be used for very small items

Repeatable color

Disadvantages: High cost per square foot (4 color output $3-$7 per square foot

Requires a dust free environment (see below for reasons why)*

Large initial investment

Large investment in materials inventory

The technology and features of specific machines are discussed below:

Gerber Edge: Advantages Low cost per square foot $3/foot

On graphics 12" wide or less, no seaming marks

Many Spot colors available

Disadvantages: Small size (12"print width)

Manually change each color

High cost…About $20,000

Roland Color Camm: Advantages: Automatically changes colors

Wide format (24")

Built in vinyl cutter to contour cut graphics

Low initial cost ($7,500)

600 dpi output

Disadvantages: High cost per square foot $7 for full color

Seams are evident every ½" when viewed closely

Few spot colors available

Sumachrome, DuraChrome, Gerber Maxx (all use similar technology)

Advantages: Automatically changes colors

Large format 24" Sumachrome, 36" Gerber, 52" Durachrome

Large ribbon width (2-6") reduces visible seams

Low cost per foot $3-$4 for 4 color output

Disadvantages High initial investment ($19,000 Sumachrome,

$44,000 Durachrome, $49,000 Gerber)

Requires clean work environment, special "dusted" material*

*Dust particles can create "holes"in an image. Additionally, dust can be dragged across the entire print path resulting in a white line or "drop".

The production process:

The production process for thermal resin printers is different than vinyl production or inkjet production. A general description of the process follows:

Photographic: Same as inkjet (Calibrate scanner, materials and output device)

Spot Color: Resin printers can use spot colors, which you can match to the desired, colors your output. Just like producing a job with vinyl, you pick the color you want, and that’s the output you get. (However, the color you see on your screen may not match the output!) If the job requires a color which does not match any existing spot colors, then you must use charts (only useful with Gerber ribbons and media), or print a color chart as you would on the inkjet side.

Handling of output: The output is immediately dry and ready for fabrication. You can use application fluids, transfer tape and when printed on vinyl, you can use the same fabrication techniques.

Best Uses of Thermal Resin Output: Vehicle graphics, small cut out lettering, decals.

Inkjet Technology

Inkjet technology includes both solvent based and waterbased printers. The water based printers are the most common and affordable. Newer solvent based machines start at $15,000, whereas, water based inkjet machines are available starting at $1,500.

Inkjet machines spray tiny droplets of ink on specially treated substrates. Inkjet inks can be either be dye based (without pigments) or pigmented (which have tiny solid particles suspended in the solution). Dye based inks often include a UV (ultraviolet light) inhibitor to increase longevity in sunny locations. Water based inkjet output can be waterproof when printed on specially treated substrates, provided that, the inks and media are compatible. Normally, inkjet output is not waterproof and can be damaged by exposure to water or water based liquids. For this reason, much of the output from inkjet printers is laminated for protection. Solvent and eco-solvent machines are waterproof on vinyl type materials (vinyls and banner material) All output must be laminated for vehicle use.

Advantages: Water based Prints on a wide range of treated substrates, including papers, vinyls, cloth, banner stock, canvas, etc. (solvent based only on vinyl type materials)

Photographic quality when printed on photo grade papers

Long UV life (3+ years when using Pigmented inks and UV laminate)

Low production cost (as low as 25 cents per foot for paper)

Large size (Up to 6’ wide printers available)

Low initial investment ($7,000 -$10,000 for a 36" printer and laminator) (Solvent based starting at $13,000)

Disadvantages: Outdoor long term use requires lamination

Outdoor life slightly less than resin output

Lamination can substantially increase cost per square foot.

Cost per square foot on an Encad printer using various substrates. Lower cost materials are also available:

Material	Ink Cost	Material Cost	Laminate Cost	Total Cost
Plain Paper (SIHL or AZON)	$.17 @50% Coverage	.$.08 - $.16 /ft	Why bother?	$.25-$.33 per foot
Outdoor Vinyl (3m)	$.55 @100% Coverage*	$1.40/ft (3M Material)	$.61/ft (3m Material)	$2.56 /ft Using 3M
Waterproof Vinyl (SIHL)	$.55 @100% Coverage*	$1.33/ft	Not needed	$1.88/ft
Photographic Paper (SIHL)	$.35 @100% Coverage	$.40/ft	$.18 (3mil thermal)	$..88
Canvas (Encad)	$.35 @100% Coverage	$2.08/ft	Clear coat only	$2.43
Waterproof Banner (Advantage)	$.27 (50% Coverage)*	$1.00/ft	Not Needed	$1.27

*Outdoor Pigmented Inks

The production process. A general description of the process follows:

Photographic: Calibrate scanner, materials and output device, print color charts on each material to insure accurate vector color reproduction. Use brand name inks and media to insure consistent color reproduction.

Spot Color: Ink Jet printers use CMYK (Cyan, Magenta, Yellow and Black) inks to produce the color gamut. Metallic colors can be simulated, but not reproduced exactly. No white color available, unable to print on dark substrates. (Print on vinyl then apply)

Handling of output: The output must be laminated for long term outdoor durability. Most materials will be damaged when exposed to water. (Treat the same way as you would treat a photograph). May be clear coated with any oil or solvent based clear coat.

Best Uses of Inkjet Output: Vehicle graphics (one foot or larger) trade show graphics, retail store graphics, promotional window graphics, show cards, window lettering, banners, magnetic signs, menu signs.

Available Equipment: Printers are available from Encad, Hewlett Packard, Roland, Graphtec and others.. (Stick to the brand names!) When looking for equipment, a quick change between pigmented and dye based inks is desirable. Two recommended machines are:

Encad 1000i -High Speed water Based Printer-About $10,000

Roland VersaCamm 30" ecosolvent printer $13,000

Lamination: There are two types of laminators available: Cold or Thermal (also combination machines!). Thermal laminators have a lower cost per square foot ($.18 vs $.65 for 3 mil) In general, cold laminators achieve a higher rate of success than thermal laminators when laminating ink jet output. Thermal laminators encapsulate (both sides) an image, and are easier to use. Thermal laminators can be an additional profit center for a company. It is recommended that cold laminates be applied to vinyls for long term outdoor applications.

Sample pricing of laminators:

Printloc Pro 40" cold laminator $4,200

Printloc Pro Thermal Laminator $3,400

Seal 410 Cold and thermal laminator $9,500

Total price for a 36" inkjet system including printer and laminator ranges from $9,400 to $17,000.

Product Usage Matrix:

	Resin Printing	Inkjet Printing	Laminated inkjet printing	Other Process
Decals (Short Run)	Best	Not Recommended	Not Recommended
Vehicle Graphics 12" or larger	Good	Not Recommended	Best
Window Signs	Not Recommended	Good	Best
Trade Show Signs	Fair	Good	Best
Magnetic Signs	Good	Not Recommended	Good
Retail Store Graphics	Fair	Good	Best
Boat Graphics	Not Recommended	Not Recommended	Not Recommended
Window Lettering	Good	Not Recommended	Good (12" or larger)
Exterior Lighted Signs	Not Recommended	Not Recommended	Not Recommended	Vinyl or Screen
Interior Lighted signs	Not Recommended	Good	Best
Banners	Not Recommended	Best (waterproof)	Good