Overlaminates: Under the Microscope

The technological evolution of overlaminates shows no sign of slowing, with new manufacturing advancements continually ushering in new thicknesses, textures, and product capabilities. Those trends in turn are helping suggest new ways to use the products, and new means of print service providers (PSPs) profiting from their use.

Few understand the ongoing metamorphosis of the technology and the market better than Tammy Bui. As product manager for Arlon Graphics, a manufacturer of innovative cast and pressure-sensitive vinyl products for a wide range of visual expressions, Bui has scrutinized developments in the space carefully.

Today’s key trends, she said, include expansion of vehicle fleet opportunities resulting from the cost effectiveness of overlaminate vehicle wraps, and an increasing tendency to use overlaminates in wall coverings to replace wallpaper.

“At Arlon, we’re seeing growth in the fleet business, as people switch out their graphics on an annual or even monthly basis on up to 100 vehicles per company,” she said. “It’s more cost-effective than before. The reason is that the vinyl film technology has gotten to the point where it’s more cost efficient to replace vinyl wrap than to paint the cars or buy new ones. They’re easy to customize and you can really provide the customers with what they need and want.”

Many of Arlon’s customers are also entering the profitable and fast-growing wall coverings market, where wallpaper is being replaced with different overlaminates, such as textured vinyl that would be overlaid on white or colored vinyl, Bui said.

Why is this market growing? “There is more control with the design of the product,” she explained. “Now, with wallpaper, you have to buy a set custom texture or color. But with these [overlaminate] products you have more creativity and more control, and can work alongside interior designers. I see it growing more commercially, in restaurants and any type of business. But it could grow in residential use as well.”        

New overlaminates are often introduced as a second wave of innovation, after the latest base materials have already been introduced to the market, said Adam Larson, global portfolio manager, Premium Films with 3M Commercial Solutions. “With innovations in the ink world leading to formulations that add an extra bit [of] strain on overlaminates, manufacturers have the opportunity to optimize these products and provide similar technological advancements,” he said.

“Instant turnaround” printing processes can limit an overlaminate’s ability to adhere properly to the ink when set on a base film as soon as possible after printing.

New inks designed to be more scratch resistant add another factor in what overlaminate manufacturers must consider when designing new products. However, new technologies and processes open opportunities for 3M to leverage its knowledge in adhesive technology, and continue to lead in overlaminate innovation, Larson said.  

New products

New products are helping make overlaminates a more intriguing opportunity than ever before for PSPs. Arlon Graphics recently introduced its Series 3270 overlaminate, a 2-mil. clear glossy PVC film, developed in conjunction with the company's SLX Cast Wrap Film with FLITE technology, Bui said. “It was first designed for our fleet market, to make application much easier for installers,” she reported. “It provides the right amount of body to allow installers to drape the film over and install to the vehicle. It also provides gloss that's consistent throughout the roll, enhancing the print and providing an overall better visual [representation] of the printed graphics.”

Today, there is greater use of non-PVC film, a more environmentally friendly solution that doesn't have chlorine or solvent and is more compliant with international regulations. Common non-PVC options include acrylic and or polyurethane-based films.

Said Bui: “Both acrylic films and polyurethane films are more expensive than PVC films. I like to correlate it to organic foods sold in supermarkets.”

But non-PVC films can actually extend the lifetime of printed products by up to five years, depending on the thickness of the film, and can provide abrasion and scratch resistance. Arlon offers its Series 3350, a 2-mil. anti-graffiti laminate. This PVDF film can be used in point-of-purchase displays, backlit signs, and additional display graphics.

Arlon's Series 3310 is a 1.5-mil. polyurethane overlaminate used for digital print products applied to vehicles, displays for multi-purpose commercial use, and anything requiring abrasion resistance, Bui reported.

Joseph C. Barnard, product manager, digital print media with Avery Dennison Graphics Solutions, also sees alternative overlaminates’ emergence as a key trend to watch. “Overlaminates for pressure-sensitive PVC films have traditionally been clear,” he said. “There are a number of factors such as sustainability, responsible sourcing, extended durability, and other performance characteristics that are driving alternative overlaminate films like urethanes. Although traditional PVC overlaminates are still by far the dominant choice, the demand for specialty overlaminates has increased over the past few years. Not only has there been a shift in materials, but also with special effects such as sparkle and colored overlaminates.”

Drytac company officials believe an array of new technological opportunities exist in the sector.

For example, Drytac’s line of ProTac products add many revenue generating benefits, said vice president of sales and marketing Darren Speizer. ProTac Anti-Bacterial film allows a durable anti-bacterial additive that offers reliable protection against mold and mildew growth and bacterial contamination.

“This is ideal for use in environments where hygiene is of importance, such as schools, nurseries, communal buildings, restaurants, cafeterias, vending applications, and hospitals,” he said. “Another example is seen in Protac Anti-Graffiti, which is an outdoor, graffiti-resistant, gloss finish overlaminating film impervious to UV, dirt, and pollutants. This overlaminate offers superb clarity, detail, and color contrast. Protac Emerytex showcases new technology through its scuff-resistant finish, which makes it suitable for graphics where extensive handling may be involved.” 

The anti-slip properties of Protac Emerytex have been tested, approved, and are recommended for floor graphics, Speizer said. They are, he added, “ideal for laminating mousepads, counter graphics, and mounted prints to be displayed in high-traffic areas.”

If there’s a market that involves a wrap film, overlaminates generally follow suit, Larson observed. “That being said, apart from the traditional installation mediums like vehicles, signs, and exteriors, interior walls are a market that has seen a recent expansion in overlaminate innovation,” he reported. The new 3M Décor Overlaminate 8600 Series offers five new cast vinyl décor overlaminates that help add warmth, style, and professionalism to interior spaces. The matte finishes in Classic Linen, Knit, White Fir, Riverbed, and Plaster protect underlying graphics and create a unique aesthetic and depth that can transform interiors into more visually engaging environments.

The future

Current trends toward new materials and different effects should be expected to continue, and Avery Dennison is continually innovating in these areas, Barnard said. “The latest innovation is colored overlaminates for Conform Chrome films,” he added.

“[They] provide a protection and a totally new appearance. For example, a purple-colored overlaminate over Conform Chrome Silver makes for a shiny, metallic purple that is a much different look from the original silver of the base film.”

In addition, use of graphics in retail settings is increasing rapidly, Speizer said. Graphics are not just seen in shopping malls, but in parking garages and floors leading to elevators. “In order to keep up with current trends the appropriate adhesive must be combined with the correct laminate to reach the desired outcome,” he advised.

PSPs should stay in close touch with laminate manufacturers to ensure they remain up to date on current and soon-to-arrive market opportunities, he added. “With the introduction of new markets, such as hospitals, restaurants, schools, and other public areas, PSPs need to stay informed as to not miss an opportunity for adding value and generating revenue with finishing opportunities,” he said.

One big trend in overlaminate innovation is the expansion of products that offer texture or added visual elements to a base film, Larson said.

Along with Décor Overlaminate 8600 Series, 3M Wrap Overlaminate Series 8900 is another specialty product line that can enhance any base film with a sparkle, brushed, or carbon fiber aesthetic. Usually seen in the vehicle space, the 8900 Series can be mixed with various color change or base print films, to unearth huge creative potential.

Also noticeably increased are the warranties for overlaminates. For Décor Overlaminate 8600 Series, 3M offers the 3M MCS Warranty for Finished Graphics, the first of its kind to be introduced in the marketplace. “The warranty covers the graphics installed on smooth interior walls for up to eight years,” Larson said.

Arlon's Bui said her company is focused on growing its vehicle fleet market, and also going beyond vehicles to other transportation applications, such as boats, trains, trailers, and tankers. “There are so many forms of transportation out there, and we want to reach them all,” she reported “We're also continuing to develop and grow our wall wrap applications. We want to expand our line of high-tack wall products, which [refers to] an increasingly popular wall wrap for low-surface energy substrates.

All in all, she added, the future is pretty exciting.