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I guess I'm in the minority- I've seen plenty of print/install failures due to not enough outgassing time. It's not that the laminate fails (normally), it's that the gasses migrate the path of least resistance. Once the print is laminated, that least resistance is through the print media, which...

Spring for the corrugated plastic that's made for digital printing. It's actually square and the manufacturing conditions provide a clean sheet that (usually) doesn't need anything extra for use. Even with the slight difference in cost between it and "regular" coroplast, you're still saving...

The only thing I can think is that your margins are larger than you realize, or the file is wonky. If it's not your margins, maybe try saving the file as a PDF or a PSD and see if it lets you print correctly. It's a pain, but that's fixed a few weird errors for us in the RIP.

Try an adhesive promoter or spring for the "digital" coroplast that most suppliers offer some version of. The ink tends to adhere better, and the panels are actually square and clean.

Oh, if only it were that simple with CNC! Does this table have a vacuum hold-down? That's always my first suspect- poor quality because the material is moving due to not being stationary on the table. After that, start simple and check the lubrication as johnnysigns mentioned. If that's not...

Most plastic suppliers will have large rolls of polycarbonate. I suggest that, because a piece of acrylic that size will be expensive- and fragile. If you do go with two pieces of acrylic, use an overlapping seam (not a butt seam) and, whatever you do, do not rely on vinyl to hold anything together.

This^^^. All day long.

This is my preferred method. And then you run into the installer who's not smart enough to use this method. It doesn't make me want to beat my head against the wall- it makes me want to beat their head against the wall.

Maybe I'm not thinking enough, but why not build it normally (with white acrylic faces) and use green LEDs? Or is that not the green they want? Alternately, 3M Dual Color White on milky white acrylic with green LEDS (which would allow more of the LEDs' green to come through).

If I misunderstood your post, my apologies- but if I wouldn't even consider a production machine that wasn't backed by technical support I could actually speak to- for free- for at least six months to a year, depending on what was spent and what the equipment is- and I sure as hell wouldn't pay...

3M, Avery, and Arlon offer 60" "etched" media. Probably Oracal does, too- but I've never used it.

Not to hijack the original thread, but get a vacuum for hold down.

I won't say never use tape, because 3M's VHB is pretty impressive (as long as you get the right one)- but, with it seeming like more and more paint lines putting in additives designed to withstand things sticking to it, you're safer using at least one stud. If you don't, you take your chances...

It depends on your RIP, for one thing... If you're using Onyx, the color has to be named Spot1. In Caldera, it has to be named White. Once everything's saved, make sure you're opening the file with one of the white enabled print profiles.

It print a number of different types of tests from the control panel. What kind of test are you trying to run?

I'd suggest an .080" or .125" aluminum backer to attach to the post. Glue/mechanically affix the HDU to the aluminum.

Use cast media/laminate if you want it to last longer. If your customer doesn't want to pay for quality, you're going to have to decide for yourself if it's worth it and your reputation can withstand the bad-mouthing they're going to do when substandard materials fail. Because they will...

Used to be pretty much any of the standard plastic suppliers had a version of it, but Spar-Tech (the manufacturers of Sta-Tuf) don't appear to make it any more. If your local plastic guys can't help, the only place I could find that still lists it for sale only was Denco.

Make sure you're using optically clear media and laminate would be my suggestion.

I was so busy noticing how the letters weren't aligned that I completely missed that. Now I can't see anything else!