Why are there bubbles everywhere under my signs?

When air and other gases collect under vinyl film and expand due to heat, they can generate enough force to eventually lift the film off the sign surface, forming small bubbles.

In some cases, the gases are escaping from paint or coatings which are not completely cured, and other times the base material itself can “outgas.” This occurs most frequently in acrylic and polycarbonate sheeting. 

These bubbles are almost always preventable and here some precautions to observe:

• Be sure paints have had plenty of time to cure in warm dry conditions.
• Be sure to let the sign substrates of thick plastic sheet stock “outgas” by removing the protective tape early in the sign making process.
• Do not apply too much wetting solution onto sign or graphic surfaces.
• Use a low or medium tack application tape if possible. However, in all cases of pre-masked graphics, reapply pressure on the graphics after removing the tape.
• Use soft squeegees or rollers to apply to rough surfaces.

If you are faced with bubbles in a finished sign:

1. Give the sign some time to breathe and the bubbles will diminish in 4 or 5 days. Note that PVC film will release trapped volatiles, but polyester and reflective films will not.
2. Pop the bubbles by poking them with a pin or dart and push the air out.