We do decal design in Illustrator, which is probably better than PS. Here's an overview:
- In SW, make a drawing of the view or views (shaded with edges) that the decal/printing is to be applied.
- export this as a PDF or AI file with high quality shaded edges turned on to output vector edges. The PDF/AI file keeps everything scaled 1:1.
- open this file in AI and design the art. Put the SW geometry on a separate layer.
- We use the artboards/crop areas in AI to control the size of the images that will be exported. We usually make the artboard centered on the face/part so that it is easy to apply the decal in SW. Then you don't have to move the decal in SW. It's simply centered.
- Then we turn off the part layer and export to PNG with transparency at 1000 dpi (1 pixel = .001 inches). A 1000 x 1000 pixel PNG will be 1 inch x 1 inch.
- Then apply the decal in sw, use decal image alpha channel to maintain the transparancy. Choose the face(s) and resize it based on the resolution (1 pixel = .001 inches)
Thanks a lot, not sure why i was focusing on photoshop instead of illustrator but thanks for pointing that out! Will give your instructions a shot, thanks again!