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Are you printing, laminating, and then cutting? I sometimes find that this is enough to distort the vinyl slightly, same as weather conditions. Where I am the weather can change 40 degrees in 24 hours and vinyl doesn't like that at all!
I don't know if you solved this yet or not. We just bought an Epson SureColor T3170X 24" Desktop Printer with Cadlnk softwear and film. We're very happy with it. It uses all black ink so the film is nice and dense.
We were actually asked to do this by a new art gallery in our city. We'd never done it before so we passed on it. If we had had more time we would have figured it out but opening day was close and we didn't want to be responsible for having to repaint a wall!
Two weeks ago I would have said that the Epson S80600 was a great machine. However, our not even two year old machine stopped working on July 9th and the service tech hasn't even made it here yet. He had to get a main board in from the US (none in Canada) . I know that it got to a tech yesterday...
We printed them long ago. You need the transfer paper , plastisol inks and a regular conveyor dryer for curing. You may also want a spot curing unit . Perhaps technology has changed since then though!
We used Drytac Spot On Floor Graphic for an event last year and it worked fine . I wouldn't use it for any social distancing decals, but promotional stuff is fun.
I use Flexi sign and while i do some of it manually, I also use the colour trapping feature in the program with decent results - at least on fairly simple things!
It is a way for employees to see the costs associated with doing a poor job on something. And of course it's factored in to the operating costs. It acts like a bonus. My husband's old boss had a similar system where he paid a certain amount into a fund each month. Mistakes were taken out of it...
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