I understand, I really do, but those of you making the assumption of using cast is the only way...... do you not remember any cast vinyl failures ??
Although it was primarily one manufacturer, it's happened to many different manufacturers. Granted, it doesn't happen often [luckily] but one never knows, huh ??
That being said, many things have changed in our shop, since we now use flatbeds and roll to roll printers. While we only stock a few colors in intermediate vinyl, I can't remember a truck or sign with it on... lasting less than 5 or 6 years. We've had great success using it and we don't consider it inferior, unless you were using it on an electric face, a permanent sign or a fleet of trucks. Then it would be dumb to use intermediate and I would agree it was an inferior product, but if the shoe fits.........
Today, if a customer wants a 4' x 4' Cor-X sign, we'd flatbed print it and it still only has a life expectancy of 1 to 2 years. However, whether it was one color or 13 million colors, it costs us the same to print it. 5 years ago we would've done that in intermediate vinyl and still made out like bandits. For us, it's all about making a happy customer.... who keeps coming back.