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Enhancing Precision in Auto Detailing: 
The Evolution from Hand-Cut Techniques to 
Cutting Software

Kavaca ION CPF installation

Each year, the popularity of car wrapping with film using software and cutting plotters increases.

This trend is associated not only with the numerous benefits identified by detailing center owners but also with the increasingly common requests from clients. Many PPF manufacturers already have their own programs for cutting film according to patterns, as they clearly understand the advantages and see the future in the development of this technology. At the same time, the shapes of these patterns for the same car are different for each manufacturer. This is due to the fact that there are several methods of producing the cutout itself.

Manual film cutting

Previously, patterns were created manually by wrapping the car with various materials and marking the edges of parts and the lines of film cuts on them. Then, this material was removed from the car part and a computer version of the template was created, after which the PPF was cut out according to the pattern on the plotter, the car was wrapped again, and adjustments were made to the pattern, and this process was repeated several times until the pattern was as correct as possible. This method was too long, and most importantly, the patterns were often not quite correct, as it depended on the skill of the designer-installer "I am an artist, this is how I see it"; the quality of the first installed mock-up film or other material, and many other factors. Also, the standard of pattern creation was completely different before, as the under-folding of the film behind the edge of the car part was rarely taken into account, leaving open areas where chips later formed.

Kavaca ION cpf pattern on a car

In the last few years, thanks to modern high-precision 3D scanning technologies and software that can turn a 3D model into an accurate 2D model, taking into account the characteristics of material elasticity, it has become possible to create maximally accurate patterns considering the complex shapes of parts, the smallest bends and under-folding of the film in the right places, the accuracy of the edge of the part, and joints with other body or interior elements of the car. It is precisely such a modern method of creating patterns that allows us to eliminate human errors and create truly accurate patterns, which will not need to be adjusted during the car wrapping process.

quality work macro cpf

And of course, the requirements of car owners for the result they want to receive after paying for an expensive service must be taken into account. In recent years, the requirement for work quality has noticeably increased; now car owners pay close attention to the work result and choose detailing studios that really work for quality. Again, the modern approach to creating patterns allows us to meet the desired quality.

In the production of KAVACA Smart Cut patterns, the most modern 3D scanners and software are used, which maximally exclude the negative impact of the human factor on the production process. When using such state-of-the-art technologies, pattern designers, together with professional installers, only test, correct, and improve the already created digital pattern if necessary. Another important fact is which particular film is used for the preliminary wrapping of elements to check the correctness of the patterns and their adjustments. After all, installers work with various PPFs, and where patterns fit well for one film, they may not fit very well for another. Specifically, to achieve maximum correctness in checking and producing patterns, we have developed a special PPF KAVACA PRECUT, which combines the averaged characteristics of more than 30 manufacturers, thus we have achieved the most comfortable installation with practically any film according to our patterns.

Kavaca Smart Cut application

Now, let's take a closer look at the benefits of using patterns for installing protective film on a car or motorcycle:

Kavaca Smart Cut AI grouping of patterns

1. The savings in material compared to manual cutting range from 25 to 35 percent, which is a significant amount considering the cost of PPF. After all, you can place elements with a distance of 1 mm between each other, while with manual cutting this distance is at least 10 centimeters. Our software has the most advanced functionality for automatic grouping of elements, developed on an AI algorithm and operating on the power of a powerful cloud server.

2. Unfortunately, most PPF installers do not have high qualifications, and when cutting the film on the car body, they cut it through, thereby usually cutting the paintwork down to the metal or plastic, at least damaging the paintwork. Then, when removing the film from a plastic element or car body, for example, after a minor accident, the paint peels off at the places of the through cut and comes off with the film. Over time, the paint on aluminum parts begins to bubble at the site of the cut. On metal, it rusts.

Kavaca Smart Cut application screenshot

Many car owners have already faced this and it is one of the reasons why they want to wrap their car or motorcycle with pre-cut patterns. The process of cutting the film on the car cannot be controlled by the business owner, as the quality result of this responsible work depends on many factors, such as the sharpness of the blades, the blade manufacturer, the mood and especially the skill of the worker, and many other factors. As a result, the car receives significant paintwork damage at the very first stage of "protection". The only way to avoid problems with customers on this issue and to ensure peace of mind is to use pattern technology.

3. Another common cause of customer dissatisfaction is various shortcomings and breakdowns of elements during their disassembly for wrapping.

Kavaca ION installation on white car

For example, to wrap a door manually, it is often necessary to remove handles or mirrors, and often for this, it is necessary to dismantle the inner door trim, which usually leads to unpleasant surprises in the form of broken small parts, etc. When removing various emblems, the paint is often scratched under them or around them, and when reinstalling them, double-sided tape thicker than the original is used, and as a result, this does not look very nice, especially on small or complex-shaped emblems. When trying to cut the film around emblems without removing them, as a rule, there are cuts and an uneven contour. In addition to the above negative facts during disassembly, possible errors in the electronics operation after poor-quality assembly or due to the features of a particular car can be added. And always remember that no element after dismantling will be installed back the same way as it was at the factory during assembly. We also add additional time for dismantling/mounting here.

4. When wrapping with KAVACA Smart Cut patterns, you have absolutely even beautiful edges everywhere, which is impossible to achieve with manual cutting.

Car macro photo with Kavaca ION

5. Sometimes (most often on bumpers of complex shapes) it is necessary to join elements together, and again, with manual cutting, it is never possible to achieve a perfect seam when joining. Cutting around various inserts in the bumper, parking sensors, and the like with hand cutting always leaves much to be desired.

Kavaca ION on a small element of car

6. Recently, it has become customary to wrap small elements of the car, such as small details in bumpers and rearview mirrors, chrome elements, moldings around windows, interior elements. In addition to the fact that work with patterns is performed up to 10 times faster, you also get the perfect shape of these parts.

7. Saving workspace is another plus of using plotter cutting, as only two square meters of space is needed to install the equipment, unlike the larger area required for manual cutting.

plotter in the cutting process

8. Every business owner strives to earn more and more money, and in addition to the aforementioned significant savings in material, the use of patterns also provides an overall saving of time on car wrapping by more than twice, thereby increasing the throughput of the detailing center.

Kavaca ION simple installation

9. Another nice bonus is the qualification of the personnel, as wrapping with patterns is much simpler and does not require as high a level of professionalism from workers as with conventional manual wrapping, which simplifies the search and training of personnel.

10. To maximize the efficiency of working with patterns, we have developed a new generation film KAVACA ION using CPF technology. In its development, we took into account all the nuances for installation with patterns. It is very elastic, but at the same time, the Top Coat has moderate hardness. The adhesive base, not typical for anti-gravel films, allows for turns without the use of primer, even with a size of 1-2 mm. Our two new products are aimed at freeing you from many problems associated with the installation of protective film, reducing costs, and bringing additional significant income to your business.

Kavaca ION macro photo. ION exchange technology

In conclusion, the use of patterns for car wrapping with protective film brings significant benefits to both car owners and detailing business owners. Car owners can be assured of a flawless fit and protection of their vehicle without the risk of paint or body damage, which is often the result of manual cutting. They also receive a high-quality result that matches their investment in protecting their car. For businesses, patterns speed up the wrapping process, reduce material costs, time, and overall expenses, and also minimize errors, thereby increasing profitability and detailing center capacity. It also simplifies the requirements for personnel skills, allowing the use of and finding less experienced employees without compromising on quality. Overall, the Kavaca Smart Cut pattern technology optimizes processes and improves the final quality, strengthening customer trust and contributing to business growth.

Kavaca ION set unboxing. Ceramic Pro ION top coat

Let the Kavaca Smart Cut pattern technology and KAVACA ION protective film become the key to success for your business and a reliable shield for your clients' cars, ensuring impeccable quality and durability of each wrap.

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