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You said you are using a big squeegee, for your first pass it works but you still need to use a regular small squeegee like 3m gold to remove all of your water bubbles if you don't have a laminator.
Start by checking out the printer making sure the heads aren't ruin. If it's still running you can do many things mainly as a hobby. Check out there websites video for the bn-20.
If you are using easy weed heat transfer then they must be using a vinyl cutter not printer if you are buying full color prints then that is different. You can get a cheap and the point here is cheap cutter with it's basic software for around $300. A small digital printer for your heat transfer...
No, first I didn't want it and second I don't think I could have done them in 1 week special anything else on top. I would have had to do (50) decals cut, weed & trim in 1 hr. to make $20. I don't think it was humanly possible...
So I had a customer request 3000 of these 4" x 4" decals to be cut masked and trimmed. I told him $3ea. and he said that someone had quoted him @ .40ea. oh and he needed them in 1 week.
Omega Panels makes an edge cap, I think you can heat it and make your curves. 2 different sizes available.
https://www.laminatorsinc.com/sites/www.laminatorsinc.com/files/pdf/sign_panel_production_guide_0317.pdf
Check out page 13
This company probably has some stuff that you are looking for;
https://www.howardindustries.com/products/post-and-panel-signs
You can also try SignComp.
I think once you start doing more signage you will find other business sectors that you can do work for like dealerships or contractors that need aluminum or directory signs that require digital prints. As for the laminator is a plus but you can start without since you mentioned you will mostly...
Ok, so your issue is when you are weeding it, the excess is lifting the cut letters try going in deeper with your cut. Temp might have something to do but it shouldn't be that bad. If you freshly cut something is the weeding easier than something you cut a few days ago.
Hey Doug, an if you have something that they can't help you with let me know, I'm sure I can help you out. I have shipped stuff out there before.
Henry Z
http://www.sign-mart.com/4-way-corner-rounder.html , I picked this up and it works like a charm up to .080 aluminum with no trouble. $419 with the arbor press.
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