What Makes a Print Durable?

A Practical View from Dan Hickford at Wallace Print

By Dan Hickford, Print Consultant – Wallace Print

Why Durability in Print Is Never Just About the Material

In the world of large format printing, “durability” is one of the most commonly used, and often misunderstood words. Clients often ask for “long-lasting signage” or “robust banners,” but durability isn’t a single feature you can tick off a list. So, What makes a print durable? It’s the result of multiple decisions working together material selection, environmental conditions, finish type, installation quality, and even handling once it’s left our hands.

I’ve worked on a number of print projects across construction sites, retail rollouts, and national campaigns. And I’ve seen firsthand how a banner that looks perfect in the studio can fail within days if the wrong material is used, or if it’s installed without care.

This article isn’t about selling the most expensive options. It’s about helping you understand what truly makes a printed product last.

The Material Isn’t the Whole Story — But It Is the Start

When we talk about durable print, it makes sense to start with the surface, the material your design is printed onto. At Wallace Print, we work with a wide range of substrates, each suited to different lifespans and site conditions.

Take Foamex, for example. It’s a PVC foam board that prints beautifully and handles well. It’s perfect for flat hoardings or indoor displays where it won’t be subjected to heavy handling or direct weather exposure. But take that same board and mount it outdoors without lamination, under direct sunlight, near heavy footfall, and you’ll start to see warping, edge damage, or surface wear.

Then there’s Correx, a fluted polypropylene sheet that’s brilliant for short-term signage. It’s lightweight, budget-friendly, and ideal for estate agent boards or event signage. But its structure makes it more susceptible to bending in strong wind, and without proper fixing, it can tear or collapse under pressure.

On the opposite end of the spectrum is Dibond, a solid aluminium composite that’s more or less built to last. It’s rigid, weather-resistant, and doesn’t warp, making it perfect for external signage that’s expected to hold its own over months or even years. It’s more expensive, yes, but when you consider longevity and brand perception, it’s often a smarter long-term investment.

Start With the Right Material

Choosing the correct substrate is the most important step in achieving durability. Each print material has different properties, and using the wrong one (even by accident) can compromise the whole job.

Common Substrates We Recommend:

• Foamex: Rigid, affordable, great for indoor and short to mid-term outdoor signage.
  → Explore Foamex Sign Printing
  
• Correx: Lightweight and cost-effective, ideal for temporary outdoor signage (e.g. events, estate boards).
  → Explore Correx Sign Printing
  
• Dibond (ACM): The most durable for outdoor use. Aluminium composite that’s long-lasting, weatherproof and premium-looking.
  → Explore Dibond Signs

You can explore the full range of materials we work with, including Foamex, Correx, and Dibond.

“Durability isn’t just in the thickness or cost of the board. It’s about using the right material in the right place — and knowing where the risks are.”

— Dan Hickford, Print Consultant

The Role of Environment: Indoors Isn’t Always Easy

One of the first questions I ask clients is: Where is this going? That alone changes everything.

External sites face far more variables — sun, rain, wind, temperature swings. But indoor spaces come with their own risks too. Heavy footfall, dry heat, or constant cleaning can affect even high-quality prints. A floor graphic in a retail setting, for example, might wear out faster than an outdoor banner simply because of repeated traffic.

A piece of banner PVC might last six months on a quiet fence line, but use it on scaffolding without wind slits, and it could tear within a week. For those situations, we’d often recommend mesh PVC instead, it allows air to pass through, reducing tension and stress on the fixing points.

In urban environments, where prints are exposed to pollution, vandalism, or cleaning chemicals, we frequently suggest anti-graffiti laminates to extend lifespan and preserve clarity.

“Think of the environment like wear-and-tear. The more unpredictable the space, the more control you need over how the print is finished and installed.”

— John Lidbury, Client Services Manager

Finish First: It’s Not Just for Looks

A surprising number of clients assume finishes are cosmetic, a choice between matt or gloss. But for us, finish is a protective layer, just as important as the substrate itself.

Laminates and coatings shield against:

• Matt / Gloss Laminates – Guard against UV fade and surface damage
• Anti-Graffiti Film – Ideal for city sites or transport hubs
• Seal Coats – Used on floor graphics or printable vinyl
• Hemmed & Eyeletted Edges – Standard on all outdoor banners

Depending on the material and use case, we might apply a matt laminate to reduce glare on hoardings, or a high-gloss anti-graffiti finish for city signage. Anti-graffiti laminate isn’t about fear — it’s about planning for what might happen, especially on long-term installs.

Finishing also adds structural integrity. A sealed edge or overlaminate can make a board stiffer, less prone to curling, and more resistant to delamination.

Installation: The Last Step That Makes the Biggest Difference

You can print on the best substrate, apply the most advanced laminate, and still lose all that effort through poor installation. We’ve seen print fail in 24 hours simply because it was taped to a damp, flaking ply. It peeled away from the surface before anyone even saw it.

Our print installation team is trained to spot these problems before they become issues. We use the right fixings, clean and prepare surfaces thoroughly, and always account for movement, tension, and weight.

Even something as simple as rolling a banner correctly can affect its longevity. Print should be rolled print-side out, loosely, and stored in dry, stable conditions. It sounds minor, but those choices add weeks, even months, to a product’s life.

Key Takeaways

If there’s one thing I want readers to remember, it’s this: durability is designed in, not added on later.

To create print that lasts:

• Choose your material based on use, not cost or guesswork
• Plan for the environment — UV, wind, cleaning, vandalism
• Use protective finishes like lamination or anti-graffiti coatings
• Ensure the installation is as professional as the print itself
• Handle, transport and store everything with care
  

The good news? You don’t have to figure this out alone. That’s what we’re here for. Give us a call, send us an email or drop us a form.

Ready to Make Your Print Last?

We’re always happy to help you choose the right material, finish, and install plan for your job. Whether you need a long-term hoarding solution or just want your event graphics to survive the weekend, we’ll guide you through it.

👉 Get in touch with Dan Hickford
👉 Browse our full material range
👉 Explore our installation services

About Our Contributors

Dan Hickford is a Print Consultant at Wallace Print with over 5 years of hands-on experience in specifying materials and advising clients on real-world applications. His knowledge spans every step of the process — from consultation to installation — ensuring clients get print that not only looks good, but performs under pressure.

Contributing Comment:
John Lidbury, Client Services Manager
John supports the delivery and coordination of Wallace Print’s most complex jobs, bringing a logistical lens to every recommendation we make.