Surface decoration has become very important for adding value to the finish product and while the segment remains the same the range of applications have diversified giving more option for value addition…
Embroidery
With an increase in the range of embroidery technology available, the possibilities in design and application for surface decoration have increased multifold. Today, there is choice of single and multiple head machines; each head containing multiple needles, and each of which can sew a different colour. Some multiple head machines now have selective head switch-off, allowing apparent variable head spacing. For greater flexibility, some multiple heads offer modularity by enabling different heads to embroider different designs. Increasingly, sophisticated software is also coming to the market to compliment the machines for maximum innovation of design.
[bleft]Apart from special weaves, knits, dyeing, printing and fabric finishing effects, surface decoration techniques on garments like printing, embroidery, decorative sewing, and add-ons augment the look of a product. This is further aided with a wealth of different threads, fabrics for appliqué, trims, dyes and inks that enhance the decoration. New technology is adding the increase in possibilities of surface decorations[/bleft]
The versatility of embroidery machines are enhanced with the use of attachments enabling automatic attachment of a wide array of fancy yarns, ribbons, cords, chains, sequins, as well as colour and height adjustable chenille stitch loops. Machines for special embroidery techniques like tufted embroidery are also available. Lasers further enhance the embroidery effect possibilities for cutting embroidery appliqués, holes, emblems and labels. This technique is also used for garment decoration by its own for burning and engraving patterns directly on to the fabric, especially when used with thicker fabrics such as leather, plastic, and denim. Machines for embossing three-dimensional designs using metal moulds have also been developed.
Digital Print
Moving away from traditional printing methods, direct to garment digital printing enables high production speed, excellent print quality, value addition, unlimited personalization and customization at a low unit cost, whilst new inks provide for durable soft handle, dark garment printing, and high image quality. Digital printing is not designed to replace high production screen printing but is aimed at fast moving shorter run flexible production. It is breathable and comfortable for the wearer and rivals two-stage, sublimation printing in both feel and appearance. Unlike other forms of print images it can be scaled to match the garment size without adding cost. In other methods of printing a standard size print image is normally used to cover a range of sizes, the resulting image does not therefore necessarily appear in proper proportion to the size of the garment. With digital printing, at the click of a mouse, the image can be scaled to match the garment from a child’s extra small to a full size tripleXL.
Decorative Sewing Machine
Conventional sewing machines too now have features that add surface decoration on to garments, such as a computer-controlled, lockstitch high-speed zigzag sewing machine which can produce many pattern variations including straight, zigzag, double zigzag and triple zigzag stitches in different threads. Custom patterns can also be created stitch by stitch and stored in the stitching-program. Overlockers have been adapted for decorative stitching on the edge of fabric whilst an angled two needle, four thread interlock machine has been developed to produce decorative effects on both under and outerwear. The range of specially developed shirring and smocking machines continues to diversify and expand giving new directions to the design possibilities.
Surface add-ons
Snap fasteners, poppers, rivets, spangle, rhinestones, nail heads, etc. are being increasingly used on their own or mixed with many other forms of decoration to ornament garments. The application of these add-ons is becoming easier, cheaper and more durable with new machines entering the market. High frequency welded graphics, PVC’s, flocktransfers and many other methods of transferring material via heat offer the designer further scope for decorating garments.
Among the more innovative options, one computerised hot fix spangle machine provides the ability of making spangle motifs with eleven colours and shapes of spangle in one operation. Similarly, sequins can now be stuck on to a garment quickly and securely, with full washability, rather than the conventional slower and less secure sewn method. It may not be long before an attachment for the ultrasonic and hot fixing of stones is programmed into the embroidery package.
Electronics built into smart textiles offer a whole new concept of textile decorations; LED lights can be introduced into garments which can flash in time with music, and buttons can be added with cloth speakers to create textiles and garments which can play tunes. With so many different forms of decoration, all of which can be combined in the same garment to add maximum value and uniqueness, the sky really is the limit to the designer.
