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By Abby | 20 May 2024 | 0 Comments

The basic craft process of embroidery patches

The basic craft process of embroidered patches

According to sample/drawing -- scanning -- drawing -- printing (saving) -- electric embroidery -- gluing (soft glue, hard glue, self-adhesive glue) -- cutting edge -- burning edge/wrapping edge (wrapping edge to glue) -- quality inspection -- packaging.

The details are as follows:

Step 1: The first step is the design or sketch.
This should be a drawing, a photograph, or a previously made patch that can be reproduced on a machine. For the reproduction of embroidery, the sketch is not necessarily as precise as the finished product. We just need to know the idea or sketch, the color, and the necessary size. Unlike other ways of producing patches, it has to be redrawn so that it can be replicated. We say "repainting" because what may be painted need not be embroidered. But someone with some knowledge of embroidery and the ability to operate machines is needed to carry out this duplication work.
After the sketch is made, the fabric sample and the thread used should be approved by the user.

Step 2: When the design and color have been agreed, the design pattern will be enlarged into 6 times the size of the technical map, according to this enlarged map to be able to play a guide to the embroidery machine version. A lofter must have the skills of an artist and a graphic artist. The stitch on the drawing suggests the type and color of thread used, while taking into account some requirements made by the printer.

Step 3: It is the turn of the printer to use a special machine or computer to print the pattern. There are many ways to guide this specialized machine: from paper tape to disc, the printer will be familiar with this machine in his factory. Today, all kinds of tape, no matter what format it used to be, can be easily converted to any other format.

At this stage, the human factor is most important. Only those highly skilled and experienced patternmakers can be used as patch designers. People can verify the plate belt by various means, such as on the shuttle machine, with a proof press that can make samples, you can make the plate maker constantly watch the embroidery that is being embroidered. When using a computer, only when the ribbon is really tested and cut on the prototype, do the sample. Therefore, the printer can not be careless, but can use the display to check the pattern.
Sometimes, the customer needs to see if the sample is satisfactory, and the machine operator needs the sample to check how his product is.

Step 4: Spread the appropriate fabric on the embroidery frame, select the appropriate thread, pattern tape or disc inserted into the tape reading machine, the embroidery frame is placed at the correct starting point, and then the machine can be started. The automatic color changing device controlled by computer should stop when the pattern needs to change color and needle. The process does not end until the embroidery task is completed.

Step 5: Remove the fabric from the machine and lay it on a countertop for trimming and finishing. In order to speed up the work of individual parts of the embroidery process without needling the fabric or floating needles due to changing colors, etc., they are cut, then cut the patch and removed. This is the "manual cut" on the shuttle machine, but on the multi-head machine, whether in the embroidery process or when the scissors are at this point, they are cut together.

Patches embroidered on the shuttle machine, they are not laid on the table, but are cut directly from the fabric by hand, the other part is still attached to the fabric. The entire crest of the float line etc. is trimmed by a wire cutting device. It's a time-consuming job.
The multi-head machine can choose an automatic thread cutter to speed up the process, and the thread can be cut when the embroidery is in progress, so that there is no need to manually cut the thread, which greatly saves time.

Step 6: The fabric is sorted or molded according to size and added to the hot print film or pad, while the fabric remains a single piece.

Step 7: Cut out the patch. If the shape of the patch is irregular, cut it by hand. If the embroidery edge of the patch is symmetrical, it can be either hand-cut or die-cut. The pressure of the die cut depends on water pressure or hand stamping, and the mold is made after they are lined with the patch.

Consider the elasticity of the embroidered fabric, due to the tension of the fabric on the frame, as well as the needle back and forth through the fabric and the tension of the thread, etc. All the patch have to be cut out individually. Many factories use fast group die cutting or laser cutting methods, but they are not very effective. Therefore, the badge can only be cut one at a time. Put the bad patch aside in the process.

There is no way to avoid fraying the edges of the patch when cutting by hand. A heat-printed pad will solve some problems, but even scraping your fingernails along the edges may pull some threads loose. Laser-cut patches are the best way.

In order to cut the edge of the patch well, it should be die-cut. A non-woven material such as Pellon or plastic or thermoprint and similar paste is required for the underlay of the patch. One method used many years ago was to use a wet starch adhesive as a pad before the fabric was removed from the frame, dry overnight, and then die cut.

Step 8: Die cut the patch final request to wrap. The stitching or wrapping is done on a separate wrapping machine. Only symmetrical patch are self-bound in this way. The edger will place each patch facing the side guide and turn on the switch for edging. The overlock is on the edge of the patch to really lock the pin, so there will be no wear and tear. The edger starts the edger, walks 1/4 inch from the starting point, and cuts it off, leaving a tail.
The number of needles per inch of the side can be set, sometimes also by contract. The U.S. government requires a minimum number of stitches per inch. Damaged patches should be put aside.
It is difficult to bind some flat fabric; it needs some practical padding to make it firm and firm.
The edging machine in this industry is a standard machine.
With special components such as a short presser foot, a short feed tracker and an edge guide, speeds of up to 5500spm can be achieved. The edger places the patch on the edger one at a time, facing each other, starting at a pre-selected point. Start the machine, wrap around the edge of the patch and press the edge. If the patch is rectangular, stopping the machine at every corner of the edge to turn to the other side will also increase its cost.
Leave a 3 inch tail so that the end does not come apart, and start the next badge with a small tail. When the operator finishes wrapping the edges of each patch, they are cut open.

Step 9: Take measures to keep the residual thread left by the wrapping safe, and trim the end to about 1/4 inch. One way to do this is to paste the end on the back of the patch. Another method is to pull out the remaining end lines through the wrapping edges, with friction holding them in place.
If the ends are cut very cleanly, it is possible to pull the edges apart.

Step 10: Check the quality, quantity and packaging of the patch. In the process of patch production, each additional link will increase the investment cost. From the initial embroidery process, waste products can be produced at every step. Waste products are usually put aside without repair.

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