Vinyl & films

Cast Vinyl

The film that goes around a mirror and stays there. Thin, dimensionally stable, and the only correct answer for compound curves.

Also called	3M IJ180, Avery MPI 1105, wrap film, 2 mil cast
Thickness	About 2 mil. Thinner than calendered, which is a feature rather than a saving.
Outdoor life	Seven to ten years unlaminated for premium cast, and manufacturers commonly warrant printed cast at five to seven. It normally outlives the vehicle's ownership.
Ballpark cost	Roughly 1.50 to 2.50 dollars a square foot for printable cast wrap film.

Ballpark trade cost per square foot as of August 2026, before laminate, labour or markup. Films are bought by the roll and the per foot price moves a lot with roll width and volume, so treat these as a sanity check rather than a quote.

What it actually is

Cast from a liquid mix poured onto a casting sheet and cured through ovens. Because it is never stretched during manufacture there is no stress locked into it, which is the entire reason it does not shrink back later. Usually about 2 mil.

What it is good for

→ Full and partial vehicle wraps
→ Compound curves, bumpers, mirrors and deep recesses
→ Corrugated and riveted surfaces such as trailers and box trucks
→ Any graphic expected to last more than about five years outdoors

What to watch for

It is the expensive one and it is worth it on curves. Substituting calendered on a wrap to win a quote is how a shop ends up redoing the job at its own cost eighteen months later.

Cast film needs CAST laminate. Putting calendered laminate over cast vinyl hands all the shrinkage back to the graphic and undoes what you paid for.

Overstretching still kills it. Past roughly 30 percent the film thins, colour goes light and the adhesive gives up in a recess. Use heat and patience rather than pull.

Post heating is not optional on recesses and curves. Take it to the manufacturer's stated temperature or the film remembers its flat shape and lifts.

Printing and finishing

Solvent, eco solvent, latex and UV all print it well. Let solvent prints outgas fully before laminating, or trapped solvent forms bubbles under the laminate days later.

Quoting a job with Cast Vinyl?

The free sign price calculator prices by size and material the way a shop quotes, and the wrap calculator works out coverage before you order film. No signup on either.

Price calculator Wrap calculator

Cast Vinyl — FAQ

When do I have to use cast vinyl instead of calendered?

Any compound curve, any deep recess, any corrugation or rivet, and anything meant to last beyond about five years. Flat panels and short term work do not need it.

How long does cast vinyl last on a vehicle?

Five to seven years printed and laminated is a realistic promise, and premium cast is warranted longer. Sun exposure and whether the vehicle is garaged move the number more than the brand does.

Why is cast vinyl thinner than calendered?

Because it is poured rather than squeezed. There is no stretching in manufacture, so it can be made thin and stay dimensionally stable, which is exactly what conforming to a curve needs.

Price your films once

Set your vinyls and laminates up once in PrinterFlo and every quote prices itself by size and options, with cost, profit and margin on the line as you build it.

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