Garment Lab provides a full cycle of clothing personalization for B2B clients. The production of technical apparel and corporate uniforms requires the precise transfer of logos and graphic elements. The process divides into two directions. The first direction is industrial embroidery. The second direction incorporates modern printing technologies. Each approach has a strict standard.
Digital embroidery begins with proper digitization and continues with stabilization selected according to the fabric type. The software translates vector files into machine sewing codes. Stabilization is especially important for sportswear and elastic fabrics. The embroidery must withstand intensive movement. Special stabilizer backing layers are attached to the back of the fabric to balance the tension. We offer high quality industrial embroidery in the following formats.
Volumetric Embroidery: 3D Puff embroidery creates a relief effect. The method requires the use of special foam. The foam is placed between the fabric and the thread. The needle pierces the foam and covers it with thread. Foam with a thickness of 2 millimeters to 3 millimeters is used for optimal results. This method is ideal for large geometric figures and thick fonts. Volumetric embroidery of fine details is impossible due to the foam structure.
The complexity of the graphic design and the production volume determine the printing method. Each technology has strict production requirements regarding color separation and thermal modes.
Screen Printing Screen Printing remains the industrial standard for large volume orders. Each color requires the preparation of a separate mesh screen. Plastisol ink bonds with the fabric fibers at 160 degrees Celsius. This process ensures the maximum durability of the print against washing. The initial expenditure is high due to the production of matrices. The unit price decreases sharply for orders exceeding 100 pieces.
Direct to Film Printing: DTF or Direct to Film is a universal solution. The design is printed on a special film. Polyurethane powder is applied to the wet ink. A thermal press heats the film and transfers the print onto the clothing. This method works on any type of fabric. Polyester and cotton take the DTF print equally well.
Volumetric Film Printing: Puff DTF represents the latest technology. A special chemical composition is used instead of standard ink. During thermal processing the ink expands and gains volume. This technique creates an interesting texture on corporate hoodies and adds visual depth.
Direct to Garment Printing: DTG or Direct to Garment uses water based ink. The ink absorbs directly into the fabric. This method is best for printing photographs and complex gradients. A high cotton composition in the fabric is a necessary requirement. The minimum cotton content must be 80 percent for a high quality result.
The production process begins with receiving the correct digital file. Clients must provide logos strictly in vector formats. Acceptable formats include AI, PDF, and EPS files. Specifying colors using the Pantone system is mandatory for screen printing to achieve an exact visual match. The CMYK color profile is applied for DTF printing. All fonts must be converted to curves to prevent rendering errors. A correct file eliminates production delays and ensures the precise transfer of the design onto the fabric. Statistically the correct preparation of files saves 2 working days at the initial stage.
The personalization of caps and hats requires a specific engineering approach. The central seam of six panel caps creates a serious mechanical barrier for the needle. This structural characteristic limits the maximum embroidery height to 5.5 centimeters. The process requires specialized titanium needles to pierce thick seams without breaking. Volumetric 3D Puff embroidery on caps demands low machine speed to prevent fabric damage. Considering these limitations when creating a design is essential to avoid losses.
Printing with DTF technology requires exact calibration of the press. The process relies on three main variables including time, temperature, and pressure. A standard transfer requires 150 degrees Celsius for 15 seconds. High temperatures on polyester fabrics cause a dye migration problem. Polyester dye turns into gas at high temperatures and colors the print applied on top. The facility uses black carbon blockers as a base layer to prevent this chemical reaction. This method maintains the original color of the print on sportswear.
Every batch undergoes physical testing before dispatch. Corporate and work uniforms require extreme durability during daily use. The facility conducts a stretch test to check print quality. The print must return to its initial shape without cracking after maximum stretching. Embroidery is tested through an industrial wash simulation to confirm thread color stability. This internal control mechanism ensures the structural integrity of the clothing.
Verify file formats with your designer before starting production. Avoid fine texts along the central seam when adapting a design for caps. These practical steps ensure a fast and error free production process throughout the full cycle.
Our facility has 10 years of manufacturing experience. We offer small and medium volume production and professional service. You receive constant quality control and strict adherence to production deadlines.
მეილი: info@garmentlab.ge
Email:Garmentlab.tbs@gmail.com
Our facility has 10 years of manufacturing experience. We offer small and medium volume production and professional service. You receive constant quality control and strict adherence to production deadlines.