Behind the Scenes: Print Room's Embroidery Process for Headwear - From Design to Finished Garment

Behind the Scenes: Print Room's Embroidery Process for Headwear - From Design to Finished Garment

At Print Room, our commitment to quality and attention to detail sets us apart in the world of custom merchandise. Our embroidery process for headwear is no exception. This meticulous journey involves multiple stages, from the initial design to the final stitch. Here’s a comprehensive behind-the-scenes look at how we transform a concept into a beautifully embroidered piece of headwear.

1. Concept and Design

The journey begins with our talented designers in the office. Whether it’s a custom logo, a unique pattern, or a detailed illustration, our team works closely with clients to bring their vision to life.

  • Initial Consultation: We start by understanding the client's brief, including the design, colours, and headwear style to be produced.
  • Digital Mockups: Our design team creates digital mockups to help visualise how the design will look when embroidered on the headwear.
  • Client Approval: The mockup and proof are shared with the client for feedback and approval. Any necessary revisions are made to ensure complete satisfaction.
  • Digitising the Design: The approved design is sent to our expert digitiser, who digitises the design files into a format that our embroidery machines can read. This involves converting the design into a series of stitches.


2. Choosing the Threads

 


Once the design is finalised, the next step is selecting the appropriate threads. This is crucial for achieving the desired look and durability.

 

  • Thread Selection: We use Madeira threads, which are renowned for being the best in the industry. Our team assists in selecting threads that complement the design and are suitable for the headwear fabric.
  • Colour Matching: We ensure that the thread colours match the Pantone colour provided as closely as possible. This step is crucial for preserving the integrity of the design.
  • Sampling: We then test the design on sample fabric to ensure satisfaction with how it looks. If necessary, we can provide samples to our clients for approval before commencing the job

 

     


    3. Setting Up the Machines

     

     

    With the design and threads ready, we move to the production phase. Our state-of-the-art Tajima embroidery machines are prepared for the task.

    • Marking up: Each hat is marked with fabric chalk to ensure the placement is in exactly the right position (many in our industry avoid this step to save time—we don’t!).
    • Hooping the Headwear: The headwear is securely placed in a hoop to keep it taut during the embroidery process. Proper hooping ensures that the design is embroidered accurately and without distortion.
    • Machine Calibration: Our machines are calibrated to the specific requirements of the design. This includes setting the correct tension, needle type, and stitch density.

     

     

     

    4. Embroidering the Headwear

     

     

    With everything set up, we can now run our first round of hats.

    • Running the Machines: Our skilled operators run the machines, closely monitoring the embroidery process. Each stitch is meticulously placed to ensure precision and quality.
    • Quality Checks: We perform regular quality checks throughout the embroidery to catch any issues early. This includes checking for thread breaks, misalignment, and other potential problems.

     

     

     

    5. Finishing Touches

     

     

    Once the embroidery is complete, the headwear undergoes a series of finishing touches to ensure it meets our high standards.

    • Trimming and Cleaning: Excess threads are trimmed, and the headwear is steamed to remove any marks from the hooping process.
    • Final Inspection: Each piece is carefully inspected to ensure that the embroidery is flawless and meets our quality criteria.
    • Packaging: The finished headwear is packaged with care, ready to be delivered to the client.

     

     

     

    6. Delivery

     

     

    The final step is delivering the beautifully embroidered headwear to our clients.

    • Shipping: We use reliable shipping methods to ensure that the headwear reaches our clients in perfect condition. We also ship for free throughout NZ - How good is that?

     

     

     

     

    At Print Room, our embroidery process blends artistry and precision. From the initial design concept to the final stitch, we are dedicated to delivering high-quality embroidered headwear that exceeds our clients' expectations. Thank you for trusting us with your custom embroidery needs!

     

    For more inspiration and information on embroidered headwear for your next project, fill out our contact form on our website or check out our Instagram.

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