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We had to measure up these the other day, can't imagine how it could have been done without. Saves a lot of time for quick quote as well, you don't need two people taking exact measurements for every survey.
My guess would be that your client had some screen printed items in the past where he could choose between CMYK (probably he had a gradient or fade) or they offered a lower prince for spot color print (premixed ink). So if you looked at your client like he's stupid, you were right.
Happens to me in cold weather if I leave media in printer overnight, just take it out at the end of the day or leave 20 inches unprinted next day. Never happens twice a day no matter how long the pause is between prints.
A step-up from cutter plotters would be a zund machine. If you want to go full speed you need a clamshell die-cutter like
https://www.pressdepo.com/machine/en-60721/tatming-clamshell-die-cutter-35x47
combined with an automatic screen printer like...
You need a roller like this: https://www.digiprint-supplies.com/en/rollepro-vinyl-applicator-tvigf8709 , a heatgun and a lot of patience heating up every edge. Other than that in my experience any decent vinyl will work, it doesn't need to be cast.
Make sure you don't have exposed laminate on the side of the print, slow cutting and travel down. The length of the usb makes no difference, if the data is there it's there, if it's not there your cutter won't even start cutting.
If you have the original piece you can make a copy pretty easily. Just make a silicon mould and pour resin. There are tons on youtube videos in the theme.
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