Dismantling the entire process of making PVC signs, from design to finished product, taking you through the process step by step

Hey, speaking of PVC signs, we can see them everywhere when we go shopping, do errands, and go to shopping malls. This thing looks simple, isn't it just a plastic sign? But if you really want to make a PVC sign from scratch and make it both beautiful and durable, there are many ways to do it. Today we will not deal with the fictitious ones, put aside the high-level theory, and actually go over how the PVC sign is "born". If you are thinking about customization, or are simply curious, this article may be able to explain it clearly to you.

first step: Requirements communication and design finalization - the starting point of all good products

This first step is often the most critical and the most likely to go wrong. Don't underestimate the word "communication". We have received many orders. The customer said at the beginning, "I want a brand, rectangular, just print the words on it." However, when the design drawing came out, it was discovered that the size was wrong, the color was off, and the information arrangement was unreasonable... The back and forth wasted time.

A reliable producer will confirm with you repeatedly: Where is this brand used? (Indoor or outdoor? Wind and sun? ) What is the size? (Not based on feeling, it must be accurate to centimeters and millimeters) What is the main message you want to convey? (Brand identity, guidance, or advertising? ) Are there any corporate VI color cards or special font requirements? What's the approximate budget?

Only after we have discussed all these thoroughly can designers start to work. The design process is now basically completed on the computer. Software such as CorelDRAW and Illustrator are commonly used. Why? Because they are vector drawings, they will not be distorted when enlarged or reduced, and can be accurately recognized by machines in the later stage. The design draft must fully consider the post-production process, such as which places should be raised (relief effect), which colors should be superimposed, and whether the structure of the hollow parts is solid. After the draft comes out, both parties confirm their signature (or confirm by email), and then it is considered final. Don’t rush this step. If the drawing is wrong, all the rest will be in vain.

Step 2: Material selection and panel processing - laying a good foundation

After the design is decided, it’s time to choose materials. PVC boards are actually a big family with different densities, thicknesses, hardnesses, and colors. Commonly used ones include ordinary PVC foam boards (lower density, light weight, suitable for indoors), high-quality Chevron boards (high density, harder and flatter, suitable for both indoor and outdoor use), and completely solid PVC boards (highest hardness, more expensive).

Choosing the right board according to the usage environment is a matter of knowledge. For indoor signs, ordinary boards will do and they are cheap. ； If it is to be placed outdoors, you must choose a board with good weather resistance, UV resistance, and sufficient thickness (for example, more than 5mm). Otherwise, it will be exposed to the sun and rain, and it will deform and fade in a short time. In terms of color, in addition to the common white, there are also many colored boards and even imitation wood grain and imitation marble grain boards. There are many choices.

The board comes in a large sheet. The first step is to "cut the material." According to the size of the design draft, a large cutting machine (such as a CNC engraving machine, laser cutting machine or heavy-duty cutting machine) is used to cut the large board into the required small pieces. This step pursues precision and smooth edges.

Step 3: Core processing links - engraving, printing and blister

This is the part that really reflects the "production". There are many craft options, often used in combination.:

1. Engraving and cutting ： This is one of the most commonly used techniques. Input the finalized design file into the CNC engraving machine, and the machine can automatically cut (cut out the shape) and engrave (carve patterns, text, grooves) on the PVC board. The accuracy is very high, and complex graphics are not a problem. Hollow characters and three-dimensional character effects are often achieved by it.

2. print ： If you need rich colors and images, you have to print. Screen printing It is a traditional process, suitable for orders with fewer colors and large batches. The ink has strong adhesion and is very durable. UV flatbed printing It is the current "Internet celebrity" technology that directly prints color pictures on the board. It can print any pattern and is fast. It is suitable for small batches and personalized customization. After printing, it usually needs to be covered with a layer of UV varnish or protective film to prevent sun and scratches.

3. Blister ： If you see a three-dimensional sign with a bulging effect on the surface, it is probably made of blister. The PVC board is heated and softened, and then the mold is used to adsorb and form it under vacuum. After cooling, the three-dimensional shape is obtained. It is often used to make three-dimensional brand characters, cartoon image signs, etc.

4. Grinding and polishing ： There may be burrs on the edges after cutting and engraving, which need to be smoothed manually or by machine. Especially for signs that need to be touched by hands, the edges must be rounded and not cut.

Step 4: Post-processing and assembly - details determine success or failure

The processed motherboard is not a finished product yet, it still needs to be "made up" and "assembled".

• Coloring and painting ： The recessed parts after engraving (such as engraved text) are often filled with contrasting color paint or special ink in order to make them more eye-catching. You need to be careful when filling the paint manually, otherwise it will overflow. ； Nowadays, there is also a process of machine glue dispensing.

• Painting and laminating ： Some signs need to be colored as a whole (not just part of it), and the process is spray-painted and then baked. The lamination is covered with a protective film to prevent scratches and UV rays.

• Installation accessories ： How to hang the sign? This requires "making a fuss" behind the scenes. Depending on the installation method, strong double-sided tape, inlaid magnets, slotted mounting ears, or pre-embedded nuts can be used to fix it to the wall with screws. The position of these accessories must be planned during the design, and the center of gravity balance must be considered.

Step 5: Quality inspection and packaging - the last hurdle before leaving the factory

After a sign is completed, it must undergo strict inspection. The inspection content mainly includes:: Size check (take a ruler to measure), Pattern text proofreading (There must be no typos! ), color check (Compare with design draft), Process quality inspection (Whether there are obvious scratches, burrs, dirt, bubbles, or peeling), Installation firmness test , especially bulk orders, need to be randomly inspected.

After passing the inspection, it’s time to pack. The indoor signage may be simpler and wrapped with bubble wrap to prevent scratches. ； Outdoor signs or large signs need to be properly packaged in cartons or wooden boxes with corner protectors to prevent damage during transportation. It is best to clearly indicate the product content, quantity, and "fragile" and "do not press" instructions on the packaging box.

A few final words

You see, this process is more complicated than you think? It combines material science, graphic design, machining and manual skills. Therefore, when looking for manufacturers to make PVC signs, don't just compare prices. Look at their actual cases to understand what boards and machines they use. The quality inspection process should not be formalistic. When communicating, try to be as detailed as possible about your needs. Good cooperation is the result of both parties working together.

In the final analysis, a good PVC sign should be like a silent and capable assistant, performing its mission clearly, accurately and permanently where it should appear. I hope this article can help you feel more confident next time you see or customize a PVC sign. If you have any specific questions, you are welcome to chat at any time and let's discuss it together.