Cutting Foil is a collective industry term for thin, flexible materials—typically PVC, Polyurethane (PU), or specialty polyester—that are engineered to be processed by a digital cutting plotter. These materials are manufactured with a decorative or functional top layer and a pressure-sensitive adhesive, all supported by a protective carrier sheet (liner).
Why It Matters: Impact and Use
In the signage and garment decoration sectors, the choice of cutting foil is the primary factor in a project’s durability and aesthetic finish. Identifying the correct foil type is a core technical aspect of E-E-A-T (Expertise, Authoritativeness, and Trustworthiness) for professional makers.
- Durability & Adhesion: Cutting foils are engineered for specific environments. For example, a “High-Tack” self-adhesive foil is used for low-energy plastics, while a “Super-Stretch” flex foil is required for athletic Lycra garments.
- Versatility Across Industries: Cutting foil is divided into two major categories: Heat Transfer Vinyl (HTV/Flex Foil) for textiles and Self-Adhesive Vinyl for hard surfaces (stickers and signage).
- Precision Weeding: High-quality cutting foils are designed with specific “release” properties. This allows the plotter to perform a “Kiss Cut” (cutting the foil but not the carrier), making it easy to “weed” away the excess material from intricate designs or small lettering.
- Specialty Effects: Beyond standard colors, cutting foils offer effects that are difficult to achieve via printing, such as Glitter, Reflective, Holographic, and Glow-in-the-Dark finishes.
Some examples of Cutting Foils
Technical Categories of Cutting Foil
| Category | Technical Name | Application Method | Typical Use Case |
| Flex Foil | Heat Transfer Vinyl (HTV) | Heat Press (Heat + Pressure) | T-shirts, hoodies, and sportswear. |
| Sign Vinyl | Pressure Sensitive Vinyl (PSV) | Squeegee (Manual Pressure) | Window lettering, car decals, and signs. |
| Flock Foil | Suede-textured Film | Heat Press | Retro-style apparel and thick emblems. |
Frequently Asked Questions
What is the difference between Flex foil and Sign vinyl?
Flex foil (HTV) has a heat-activated adhesive and is used for textiles. Sign vinyl has a pressure-sensitive adhesive (like a sticker) and is used for hard surfaces like glass, metal, and plastic.
Can any cutting plotter use cutting foil?
Yes, almost all hobby and professional plotters (like Roland, Graphtec, or Cricut) are designed to handle cutting foils. The key is adjusting the blade depth and pressure to match the thickness of the specific foil being used.
What does ‘weeding’ mean in relation to cutting foil?
Weeding is the process of removing the excess foil from the carrier sheet after the plotter has finished cutting your design, leaving only the parts you want to transfer.
