So are you printing onto white vinyl and trimming to the right size?
Quoted from JeffHecht:
The printing company I use has the capability to print exactly what I want (white, clear, colors, etc.) based on the artwork I provide them. I don't know the exact answer to your question, other than to say I get what I want from them
Are you just using a local shop? What kind of work do they advertise themselves as doing? I think finding the printer is probably going to be the trickiest part for people who are already comfortable doing the graphics.
BTW - I'd use Illustrator too, just because I'm more comfortable with the vector tools in it vs Photoshop's, but nothing wrong with your method if that's what you have.
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