The more high-end of Pro Safety Wear sublimation printing services is called “cut and sew all-over sublimation.” This process is similar to the pre-made garment sublimation process. However, with cut and sew sublimation, the printing is done before the garment is assembled. This process is a bit more costly — but the quality of the final product is far superior The cut and sew sublimation process produce higher quality results and provides more options for customization to make garments unique and set them apart from the competition.
The more economical of Pro Safety Wear two dye-sublimation printing processes is sublimation of pre-made, blank garments.
- Embroidery PatchesEmbroidered patches are the style most people are familiar with, having seen them on uniforms, hats, jackets, and more. Starting with a twill base, the custom design is embroidered using thread. Embroidered patches are found in three coverage amounts, 50% embroidery, 75% embroidery, and 100% embroidery. The coverage percentage refers to how much thread coverage the patch will have verses the amount of twill that will be visible. Patches that are embroidered at 50% or 75% will have a different texture, as the embroidered part will ‘rise’ off the patch.
- Woven PatchesWoven Patches are primarily used in place of embroidered patches. Since woven patches use thinner threads that are woven together instead of embroidered onto a fabric, they are ideal when a design is too detailed or complex to be achieved with the embroidery process. Woven patches are made of thread only, stitched in a continuous design. Woven patches achieve finer detail in both the design and text of the patch. Since the patch is woven, it has a smooth appearance with no raised texture. Woven patches are also a great way to achieve photographic realism. Human faces, landscapes, motorcycles, gradients, and blends can be reproduced on smaller sized woven patches in a way only possible on large embroidered patches.
- Printed PatchPrinted patches involve printing a photograph, design, or text onto a blank piece of twill fabric. Using a dye sublimation process, ink is used to fuse the design into the fabric; therefore, these patches have no colour limitation—over one million colors are available. Printed patches are completely washable, dry cleanable, and fade-proof. Small print is easily readable on these patches, and they are often the best choice for those who desire photographic realism or those needing patches in an extremely short time window, as the printing process takes less time than the embroidery process.
- Name PatchName patches are often found on work shirts or other applications where displaying a name is a professional identifier. They can be ordered as blank patches and embroidered locally or ordered finished and ready for final application. Since name patches are basic—with very little stitching and only one or two colours—they are less expensive than fully embroidered patches. Stylus Apparel offers them to you at a lower minimum than traditional embroidered patches: only four pieces per name. Additionally, you can order name patches in either embroidered or printed form.
- Chenille PatchAlso known as Letterman Patches, chenille patches are often found on varsity jackets and sweaters and are used for awards. Usually chenille patches have two layers, a bottom felt and a top that is ‘furry’ in appearance, like that of a terry cloth robe. These patches can be made to resemble custom shapes (state and county outlines, mascots, etc), as well as letters, numbers, and even full words. Chenille patches don’t achieve the same level of detail as other types of patches, but the finish can’t be replicated.
Tackle twill, or applique, involves the sewing down of material, usually a nylon twill, to clothing. Originally, the twill was laid down and sewn with a sewing machine one letter at a time and was necessarily simple to do. Today, using embroidery machines, complex combinations of embroidery and twill can be used to create intricate, 3-dimensional designs that are large, inexpensive and absolutely gorgeous. At Pro Safety Wear, we use our embroidery machines to do this sewing for several reasons. We can provide a uniformity of quality not always found in the hand-sewn variety of tackle twill. Also, we have the flexibility of using many different types of stitching on the twill or other material to give many different looks to the same designs. Quality, standard appearance and complexity of designs add to our versatility and our expert operators consider that appearance is far more important. Everything sewn should be in register and clear. It shouldn’t unravel and we do our very best to ensure that the design will outlast the clothing. Apart from that, we’re always proud of the work we do and the products we ship to you, whether it’s one single piece or a whole inventory of items. Each piece is inspected twice, once as it’s sewn and a second time as it is finished in the trimming department. Quality assurance is our primary concern, since we know that it’s what you want.
Puff 3D embroidery uses a foam underlining to achieve an extreme three-dimensional effect. The foam comes in different widths and colours to accommodate an array of products and thread colours. This application also requires the thread count to double, so that the foam will not be exposed through the thread. Puff 3D embroidery works best with block or large round shaped letters. Artwork for puff embroidery should have rounded corners so that the needle perforates the corners of the design and covers the foam completely. Thick materials that will be washed periodically generally work best with this application, such as hats, bags, and thicker jackets. To really make your artwork stand out, use our puff 3D embroidery.
Pro Safety Wear has a full-service embroidery division offering complete digitizing and embroidery services. We can supply the garments to be embroidered and give you our recommendations on the most popular brands and SKUs. We embroider and supply polo shirts, jackets, sweaters, caps, twill shirts, and anything else a needle will pierce. We are also well known for 3D/puff embroidery, etching, and distress services as well as supplying custom-made patches.