Rigid Substrates: Standing Strong

There is no overstating the importance of material choice when it comes to producing sign applications. To put it simply, if you get this wrong and opt to work with a material not well suited to the piece, or of poor quality, then the integrity of the whole job is at risk. This in turn could cost you repeat business from valuable clients.

For this reason, it is critically important that sign-makers take their time when selecting the type of material they want to work with. This is especially true when it comes to using rigid substrates, with these playing a major part in many sign projects. Only by carrying out your due diligence on the options available and speaking with specialists can you be sure that you make the right choice.

Here, we catch up with several experts within the world of rigid substrates to find out about how sign-makers can identify the solution best suited to each job and to gain an insight into some of the latest materials available to the market.

Scope for Innovation

First up is Indasol, which offers a range of technical tapes, adhesives, sealants, protection tapes, marker pens, and other consumables to the market. Owner Martin Sadler says while the company is able to support businesses across a number of industries, it has developed certain solutions especially for the sign-making sector.

Among these is Signblock, a rigid polyurethane bonding product that can be CNC cut or hand crafted to look like heavier materials such as wood and stone. The solution has been around since 2010 and has proved popular with sign-makers across all manner of sign and display applications.

“Signblock is made in such a way that it is completely bubble-free throughout,” Sadler says, adding: “Sold in 25mm thick 1m x 2m sheets, it comes in a range of densities to suit and can be laminated together to create thicker sheets using Indasol Probonder Spray Adhesive. Being bubble-free, safe to cut, and easy to paint, Signblock is like no other substrate on the market and offers huge scope for creating interesting shapes as well as regular letters and signs.

“Being lightweight, Signblock can be handled by a single operator and is easy to CNC cut and can then be lightly sanded, primed, and painted to create whatever finish the client desires. We offer the specific primer in house and as mentioned also the correct laminating adhesive to build the product up into thicker sheets.”

In terms of how Signblock is being used, Sadler offers various examples. One that stands out is when the Titanic Museum in Ireland wanted to create a detailed piece for a long-term exhibition, staff came to Indasol to discuss Signblock.

The museum initially wanted to use traditional materials such as granite or wood, but the costs were too high and from a health and safety perspective, hanging granite slabs on a wall was a concern. Sadler says Signblock allowed the museum to create a “truly stunning and timeless piece” that is still in place today.

Signblock has also been a popular choice for projects at visitor attractions such as Longleat Safari Park and Drayton Manor theme park. Again, the briefs were to have a finish looking like a traditional material, was hard wearing, easy to use, and lightweight.

An additional benefit to Signblock, particularly with large installations, is that less labour is required

“Once again, Signblock was the obvious choice and the results are quite stunning,” Sadler says, continuing: “An additional benefit to Signblock, particularly with large installations, is that less labour is required. Less hardware such as scissor lifts and time on site is greatly reduced, so the overall project costs work out far less than traditional materials.

“Furthermore, we have seen the product in higher demand over recent years with clients looking for a more environmentally friendly product, where health and safety is a concern due to traditional materials either being toxic or very heavy and where designers want to push their limits to create a more engaging and intricate piece.”

Superb Sustainability

Another specialist supplier in this market is Brett Martin. Brand marketing manager Adam Louden says the most obvious growing trend here is a requirement for sustainable substrate solutions. He explains that almost every distributor and print company now has, or has clients that have, sustainability goals that are edging closer every day and that means as a substrate manufacturer we must react and address those needs.

“Brett Martin is always looking at ways of becoming a more sustainable business whether it be via our on-site wind turbine and solar farm, circular manufacturing practices, or the use of more sustainable bio feedstocks in Brett Martin materials,” Louden says.

“There is also an increased importance on high quality sheets over low priced sheets. Of course, there is always a balance to be struck. Sign-makers have recognised that cheap, low-quality materials result in increased workload through waste and returns so are therefore looking at ways of being more efficient with their time and money, whilst also keeping their own customers happy with high quality output.”

As to what sign-makers can do to ensure they are working with quality materials, Louden says that what quality actually means varies from material to material and from job to job. That said, he explains that sign-makers should seek out products that can perform well consistently, time and time again, adding that some of the main features that make up a quality rigid product are excellent ink adhesion, flatness, and surface consistency.

“This is part of the reason why the Brett Martin Approved Partner program with the world’s leading machine manufacturers is so important, as it allows us to test and certify materials on the most popular and most current sign and display machinery in the market,” Louden explains, continuing: “The global growth of the Brett Martin Approved Partner program shows that leading manufacturers trust our products to perform under the highest demands when showcasing their machinery in the best light at events and exhibitions.

“We are always looking for new and innovative ways that Brett Martin can support our partners, and in turn their customers, and have some exciting plans for some new sustainable substrate solutions.”

Factoid: Foamalux Light Bio from Brett Martin provides a 20% carbon footprint reduction compared to its traditional foam PVC sheets

Looking at actual products from Brett Martin, the company recently launched its lower carbon PVC foam sheet, Foamalux Light Bio, which is made using a bio-attributed feedstock from the sustainable forestry industry. The substitution of bio-based resin, alongside Brett Martin’s renewable energy powered manufacturing process, provides a 20% carbon footprint reduction in comparison to its traditional foam PVC sheets.

“Foamalux Light Bio is now our second plastic substrate solution using bio feedstock following on from our Marlon BioPlus polycarbonate sheets,” Louden says, adding: “We see this as a great forward step in the plastic manufacturing industry and we will continue to explore opportunities for bio-based resin substitutes to reduce our carbon footprint.

“Foamalux Light Bio is a high quality, lower carbon, white PVC foam board that allows brands to use a sustainable substrate without compromising on quality.”

Vibrant and Evolving Market

Also in this sector, Perspex Distribution (PDL) offers a range of products. Marketing manager Luke Martyn says the markets remains as vibrant and evolving as ever, with end users seeking new and niche products that help them add value to their offering and create their own unique designs.

“Ultimately, customers are looking for reliability, both in terms of quality of product as well as continuous supply,” Martyn comments, adding: “Uniquely amongst rigid media suppliers, PDL boasts over 80% of materials being manufactured here in the UK and the only supplier to offer a basket of sign and print staples such as cast acrylic, PVC foam, aluminium composite, PETg and polycarbonate from UK suppliers.

“As UK manufacturers themselves, our customers benefit from the same UK production standards, as well as knowing that the products make a short journey from the production line to our warehouses – sometimes only a few miles.”

Taking a closer look at this range, Alupanel aluminium composite, produced in Kent by the UK’s only ACM manufacturer, is available in all grades from PDL. Whether it is a sign-maker looking for specialist traffic signage grades, or a large-format printer seeking high volume printed hoarding for a large construction project, there is an Alupanel grade perfect for the job.

For specialist projects, a new fire retardant AlupanelFR grade is now available from PDL. Not only does it meet Class B fire rating classifications, but Martyn explains that after listening to industry requirements, the double-sided substrate is manufactured with a digital matt/matt finish optimised for vibrant digital printing on its signal white surface.

Martyn goes on to say that as PDL specialises in thermoplastics, its focused core product range enables the company to hold a large stock holding of these products, both fast moving and specialist finishes, as well as offering an exemplary product knowledge to support sign-makers, printers, and fabricators
seeking the most appropriate product for their jobs.

“We believe strongly in our service and the focus enables us to best meet customer needs for a complete offer and fast turnaround,” Martyn says, adding: “Our UK supply chain also helps us to ensure customer needs are at the forefront of product development and we often take technical teams from our manufacturing partners out to visit our end users – this helps them understand the needs of the customers better and informs future product development.”

An example of this is with the Palight range of PVC Foam sheets being brought together under the Palight Plus banner. With this, Martyn says users benefit from a uniform pristine white surface across the Palight Plus, Palight Print Plus, and Palight Print Plus LW variants – leaving print service providers with more flexibility in mixing and matching sheets for their ideal applications.

“At PDL, we recently celebrated our 20-year anniversary, and each year continues to see our rigid substrate offering expand as our business grows,” Martyn adds.

If one thing is for sure, it is that there is no shortage of options when it comes to selecting and working with quality and reliable materials within the rigid substrates market. Speak with trusted suppliers and manufacturers, including those featured here, about what you are hoping to achieve with the sign applications in question and this will help you to identify the most suitable and effective solution.