Manufacturing: stage 06 of 9
In a uniform program the same mark has to reproduce identically on pique, on fleece and on woven twill. Three substrates that behave differently under a needle. Digitising and backing are selected per fabric, and a sew-out is approved before bulk.
Process
- 01
Artwork is digitised into a stitch file for the specific fabric and logo size.
- 02
Backing, density and thread are selected for the substrate.
- 03
A sew-out is produced on the bulk fabric and approved for size, placement, colour and hand feel.
- 04
Bulk embroidery runs against the approved sew-out, with checks through the run.
What you supply
- Vector artwork
- Thread colour references
- Placement and size specification per article
What you receive
- Digitised stitch file
- Approved sew-out
- Embroidered garments or panels
Risk
Every stage has a characteristic failure. Naming it is more useful than claiming it never happens.
A logo digitised for woven fabric is run on fleece and sinks into the pile.
Digitising and backing are selected per substrate, and each is approved on its own sew-out.
Dense stitching puckers a lightweight knit.
Stitch density is set for the fabric weight, and where a logo is too dense for the substrate we say so at development rather than at inspection.
Buyer questions
Digitising is a one-off setup per logo and article. Costs are confirmed with the quotation rather than published as a standard figure, because they depend on the logo complexity and the number of substrates.
The artwork stays the same, but the stitch file usually should not. Each substrate gets digitising and backing suited to it, which is what makes the finished logo look consistent across the program.
Send a specification and we will come back on construction, materials and commercial FOB costing against it.
Other manufacturing stages
Other manufacturing stages
Product Development
Development turns a reference garment, a sketch or a tech pack into a manufacturing specification the factory floor and your QA can both read the same way.
Fabric Sourcing
Fabric is usually the largest single line in an apparel cost and the hardest thing to change once a program is running.
Sampling
Sampling is where the specification is proven.