Advice for splicing/overlapping.

[Cromag]

While researching my material for a backlit sign I ran into another potential problem I had not thought of. I'll be using translucent vinyl and my finished sign will be approximately 90" x 100". I own a 24" plotter and had planned on just doing the sign in sections and overlap the edges of the sections just like I always do on oversized banners etc.

My problem is that I have learned that doing so on a backlit sign using translucent vinyl will leave a noticeable stripe where the vinyl overlaps when the sign is lit.

How do I overcome this? Is there a technique for splicing I am not aware of? On Arlon's website they refer to splicing films using a 45 degree cut. Can someone tell me how this is done or direct me to a resource where I can learn how to do this?

[player]

Can you post the layout? Also what is the image size, or inside frame measurement as opposed to the overall plastic or outside frame size?

The only way to splice it is overlap. The vinyl will shrink if you butt it up edge to edge and shortly there will be light beaming out the seams.

Depending on the color scheme, layout, letter size, background color(s) etc. I can make some practical suggestions.

I would be prepared to either sub out the vinyl to a larger plotter (very inexpensive) or plot out patterns and cut the lettering by hand. The seams need some planning, and again I would use 1/8" - 3/16" overlap.

P

[Pro Image]

I think Arlon means instead of a straight line cut either horizontal or vertical you need to cut in on a angle.........You eye tends to follow and notice a straight line and if you overlap that way you get something that will be noticed.....

I would overlap the vinyl at the most a 1/4 of a inch.........A sign that big it wont be noticeable.....................

[Pro Signs & Graphix]

Cromag,

You are correct about overlapping seams. With translucent you need to butt-splice, and yes, eventually the vinyl will shrink. This is one reason why painting backlit faces was the preferred method. Today, many print them. Depending on your layout, you still may be able to use colored translucent vinyl, which I still think is better than printing, but not painting.

[Fred Weiss]

Your best way to go is to outsource the cutting.

If you have to go with overlaps then there are two ways to go:

1. Do the overlaps and remember that you are the only one standing close to it. Everyone else views from a distance and they will not notice the darker portion. I've always had excellent aging results with a .1" overlap. .25" is thick enough to cause problems that the thinner one won't.

2. If the sign will be viewed from close enough to notice the overlap, you can do a butt joint and then overlap both sides with a high performance clear vinyl around .25" wide which will help to prevent separation from shrinkage as it ages.

[Cromag]

Thanks for the advice!

[Rich]

I would advise against paneling the translucent vinyl as it will shrink with age. Your best bet is what Fred suggests - outsourse to someone that will be able to cut it in one piece.