Case Study: A Custom Graphic Solution for Sunglass Hut

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At Graphic Systems, we pride ourselves on our ability to find custom solutions to fit our clients needs, whether it’s creating custom graphic effects or finding ways to print specialized graphic promotions quickly and economically. Earlier this year, Sunglass Hut put us to the test by asking us to create a version of a Prada graphic that could be produced at a lower cost, in large quantities, and with a quick turnaround time.

The prototype consisted of a piece of .125 clear acrylic with multiple layers of vinyl that were applied to the back of the acrylic. It also had hand cut gold foil applied to different areas of the image to give it a unique “printed on gold” visual effect. Sunglass Hut was pleased with the prototype but wanted to produce the graphic quickly and cost effectively, which was when they challenged us to find a more effective way to produce this graphic.

We readily accepted the challenge! Our first step was to create a team to work on the project from inception to completion, ensuring the consistency and quality of the project. Once assembled, our Prada team analyzed the prototype and began working on a solution that would allow us to reproduce the graphic quickly and efficiently.

They explored several different printing options including: screen printing, testing multiple substrates, and using white ink. After several days of research and testing, our team found a solution. They would:

1. Remove the “gold” areas from the digital image file so that those areas would not print on the graphic.
2. Reverse print the graphic on our two Durst Rho 800 printers on clear .020 and .125 PETG.
3. Apply white ink behind the image (minus the “gold” areas).
4. Apply a thin layer of gold foil to the back of the PETG so that the gold foil was visible through the clear areas of the graphic, creating the desired “printed on gold” effect. This also eliminated the need for hand cutting and applying the foil.

There was also an unintended positive side effect to our prototyping: printing on .020 PETG would allow us to roll the graphics for shipping, thus significantly reducing Sunglass Hut’s shipping costs! We sent our prototype to the client to get their input.

Sunglass Hut loved our solution and gave permission to proceed with the project. We ended up producing several versions of the graphic as well as managing the production of related graphics by other printers that were used for this promotion. We also managed the distribution of all the graphics via our online Promotions Management Program, ensuring that the correct graphics got to the correct locations.

The result of this exercise was that we were able to value engineer a complex graphic that met Sunglass Hut’s expectations quickly and efficiently, as well as managing the production and distribution of their entire Prada promotion.

Sunglass Hut/Prada Job Overview:

• Quantity – 1525.
• Sizes – 38” x 84”, 30x72, and 10x14.
• Material – .020 and .125 PETG.
• Print process – Reverse printed on our Durst Rho 800 using UV inks – 6 color plus 2 levels of white.
• Finishing – Gold foil backer.
• Shipping – Rolled and tubed.

Click here to request more information or give us a call at 800-235-0387 or email us at sales@graphicsystems.com