Production - Design - Manufacturing - Distribution

Fabric Imaging
There are two major processes by which images are printed on fabric: screen-printing and digital printing. Both use digital art files that are high resolution and can be manipulated to adapt the design to different layouts. Files can be formatted in Adobe Illustrator (.ai), Encapsulated Post Script (.eps) or CorelDraw (.cdr). Fonts should be included in the file and text converted to curves. Art requirements are specified in another document, please contact us for us a copy. Our graphic design services can also help clients develop original designs or convert rough sketches into digital art files.

Screen-Printing
Why Screen Printing? Simple images with only a few colors lend themselves to screen-printing. The final products are vibrant, bold and 3-dimensional. Screen-printing is a more cost-effective option for high-volume projects, which yield a lower per piece cost than digital printing as long as the number of colors is somewhat limited. A wide variety of fabrics and substrates can be used to achieve many different effects, from metallic to puff to beading. There are IFR products for indoor use that meet code for malls and schools, or those for outdoor use in any weather and environment. The longest lasting outdoor products are screen-printed UV inks on Sunbrella, a 100% acrylic fabric that is a heavy-weight canvas used in marine and awning applications, with a lifespan of 5 – 8 years. The process is environmentally friendly.

The Process. First the design is divided into different layers for each color. Then we print out film for each color layer (like camera film) which is laid against a screen covered with photographic paint, exposed in a darkroom so that the print transfers from the film to the screen, washed and dried for 24 hours. The fabric or substrate is cut to the specified size and then printed, with the ink pushed through the screen onto the cloth and then run through a high temperature dryer where the heat-sensitive inks are permanently set. The process is repeated for each color until the design is complete. The pieces are then sent to the finishing department.

Digital Printing
Why Digital? Digital printing is the proper process for complex designs with photographic images, people or many colors. The effect is nuanced and subtle with smooth gradations and tight detail. It is also cost-effective for small quantities since there is less set-up than screen printing. Only specific fabrics can be digitally printed, but there are different weights of vinyl, poly-poplins, poly-satins, poly-silks, and a wide range of light-weight options. Digital prints are generally used for indoor applications or temporary outdoor use, such as a celebration or event.

The Process. Digital printing is very much like an ink jet printer in which all 4 colors (CMYK) are applied at the same time so the final image is created in one pass. The product is dried as it is output from the digital printer and then sent for finishing.  

Finishing
Once the image is fixed, each product must be finished according to the project specifications. Project Graphics has very high standards for quality including lock-stitched hems and double-rolled pole pockets for our light-pole banners, but different projects each have specific needs and we are happy to add features such as webbing-reinforced pole pockets, extra grommets, dowels, Velcro, braiding, fringe, tassels, etc.

Display Hardware
Many products require stands, brackets or other hardware for installation. We can provide any needed mounting system and if the mounting and the graphic are purchased together then we ensure a proper fit and high quality hardware that will not damage the display. Some products, such as hanging banners, may be designed to suspend from existing fixtures or elements in the display environment. The more we know about the display environment the more useful advice we can provide about any necessary elements such as grommets, dowels or pole pockets closed with Velcro instead of being sewn shut. Other display products are designed to be used with hardware the client already owns, in which case careful measurements and perhaps blank templates are key to a proper fit.