DF - Duraflex 5 year Decal Ink 

Duraflex DF Technical Data Sheet


Duraflex DF is a UV curable ink system specifically formulated for flat, pressure sensitive decal applications requiring exterior exposure to five years. Extensive weather tests have proven Duraflex yields durable decals, which will not edge curl due to ink/vinyl shrinkage or diminish in color intensity. Duraflex maintains a remarkably high gloss finish with minimal chalking after extended weathering. This ink has been formulated with lead free, automotive grade pigments producing an extremely opaque, lightfast ink film.


• Suitable for five (5) year exterior exposure
• Exceptional opacity and high gloss for vivid, long life graphics
• Extremely flexible for multi-layer applications and die-cutting
• Low shrinkage which diminishes edge curl on long term vinyl
• Suitable with pre-mask films for easy application
• Solvent and abrasion resistant for the most severe decal uses
• Non-blocking, low tack finish for easy handling


Duraflex adheres well to pressure sensitive vinyl and print treated polyester films. Duraflex has shown excellent adhesion to a wide variety of substrates and is more flexible than most multi-purpose UV ink systems.  Additional substrates include:  electrostatic vinyl, polycarbonate, PVC, some coated metals, vinyl coated magnets, Polystyrene, and coated paper.

To determine suitability of the product for the intended use, a pretest prior to production is advised. Five (5) year durability is contingent on substrate with comparable exposure duration.

CURING: Duraflex cures well with one 200 watt per inch lamp at belt speeds between 50-60 feet (20 meters) per minute using 355-390 (140-150cm) monofilament polyester mesh.  A minimum of 175-200 mJ is required for complete cure.

Adhesion should be a minimum of 95% from curing unit with final adhesion developing within four hours of initial polymerization. Coarser fabrics can be utilized; however, cure parameters may need to be adjusted for the increased ink film.

If a loss of gloss or adhesion due to insufficient cure is noticed, the use of 5-10% DF Mixing Clear will increase light penetration and improve cure.

PRINTING: Mix well prior to every use. Although DF has been supplied in press ready condition, this system may be reduced up to 10% with DF Thinner for special viscosity adjustments.

Care should be taken to print the ink at the optimal temperature of 70°-90°F (21°- 27°C).  Cool ink will have heavier viscosity and will not flow properly whereas excessively warm ink will be lower in viscosity resulting in poor definition and decreased opacity.

SQUEEGEE:A 70-90 durometer polyurethane blade is recommended.

COVERAGE:3200 to 3600 square feet per gallon for film deposit of .40 to .60 mil.

OUTDOOR USE: Extensive accelerated weathering tests have been completed on vinyl  decals printed with Duraflex. The ink withstood 2,500 hours of exposure with 4 hour cycle times of UV light and condensation at elevated temperatures with minimal color change and marginal shrinkage.

Accelerated machine weathering are reference standards and can’t precisely reproduce actual outdoor performance. Based on prior correlation of accelerated testing versus real time exposure, 500 hours is equated to approximately one year, 4south Florida.

The use of premium grade, long term vinyl films is recommended for all applications intended to weather three years or longer.

PRE-MASK: A medium to high tack adhesive is recommended for good adhesion.

SOLAR SHIELD CLEAR: UV absorbers have been incorporated into the DF Solar Shield 
Overprint Clear, which lengthen the graphics life by acting as a sunscreen.  This clear requires more energy to cure than the normal Duraflex color range.  A minimum of 225-250 mJ is needed.

METALLICS: A superior two part system comprised of DF Metallic Mixing Clear and the proper metallic paste has been developed.  The increased viscosity of MMC helps insure a good particle suspension and our new metallic technology allow unparalleled premix shelf life and stability. The recommended mixing ratios are: 12% silver paste, 28% gold paste (by weight) to achieve the standard metallic colors. 

For optimum coverage and opacity, 280-305 (110-120 cm) plain weave monofilament mesh is recommended. Use DF Overprint Clear for extended weatherability and to improve the non-tarnishing properties of the product.

STORAGE: Care should be taken to store ink in tightly closed containers located in a cool (60°F to 80°F / 15°- 27°C), dark place. After long production runs, excess ink from the screen should be properly disposed. With suitable conditions, the ink is expected to have a shelf life of approximately 12 months from date of manufacture.

PRECAUTIONS: Read the material safety data sheet prior to processing. It contains instructions for precautions when processing, handling and storing inks, as well as first aid.  If ink comes in contact with skin, wipe ink off with a clean, dry cloth (do not use solvent).  Wash and rinse the affected area with soap and water.

PROCESS PRINTING: Duraflex halftones are available in three density levels.  Additional
control of densities may be achieved with the use of DF Halftone Extender Base.  For best results, 355 (140 cm) plain weave mesh or finer and a smooth, thin stencil coating should be utilized with four color process printing.

              PRESS    HIGH      BACKLIT
DF  Halftone Yellow            .90        1.10           1.35
DF  Halftone Magenta       1.40        1.75           2.05
DF  Halftone Cyan     1.40        1.80           2.20
DF  Halftone Black    1.60         2.00           2.25
DF  Halftone Extender Base

COLOR DURABILITY: Duraflex DF is available in twenty opaque standard colors. Custom matches, metallic, fluorescent and transparent colors are obtainable upon request.

DF-101   Primrose Yellow DF-210   Ultra Blue
DF-111   Lemon Yellow    DF-220   Emerald Green
DF-123   Medium Yellow  DF-225   Forest Green
DF-131   Brilliant Orange  DF-226   Lime Green
DF-135   Vivid Orange      DF-235   Teal
DF-141   Fire Red     DF-240   Purple
DF-151   Scarlet Red DF-260   Brown
DF-155   Rubine Red        DF-301   Opaque Black
DF-160   Rhodamine Red  DF-311   Opaque White
DF-180   Warm Red  DF-312   Dense Black
DF-190   Process Blue     DF-026    Brilliant White
DF-200   Peacock Blue     DF         Overprint Clear
DF-205   Reflex Blue DF          Metallic Mixing Clear

PANTONE MATCHING SYSTEM: The nine PANTONE approved Color Matching System shades are used to simulate the PANTONE Color Specifier 1000 colors. Formulas were designed for maximum opacity and are available in book or Imaging Color Source software format.  


DF-064    CMS GS Yellow
DF-066    CMS RS Yellow
DF-114    CMS Orange
DF-121    CMS YS Red
DF-164    CMS BS Red
DF-165    CMS Magenta
DF-127    CMS Violet
DF-230    CMS Blue
DF-325    CMS Green
DF          CMS Tinting White
DF-Shading Black

PANTONE® is a trademark of Pantone, Inc. Portions © Pantone, Inc., 1963, 1991.

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