Embroidery
Computer Role in Embroidery
Specialized Embroidery Machines have been designed to work with data from a computer. This data instructs the machine to stitch a particular design, determines the correct stitching order, indicates when to trim threads, and many other functions. In only a few minutes, the computerized embroidery machine will stitch a design with precision accuracy that no human can match for near perfect quality.
The artwork for embroidery design is entered into the computer. The computer transfers the robotics instructions necessary for stitching the design to the machine. The machine operator places the item, such as a sweatshirt or ball cap on the machine with a holder or hoop. The operator also chooses the colors of thread appropriate to the design. Once the "set up" has been performed, stitching may begin by pressing the "Start" button on the machine. It will precisely and efficiently stitch the design. A typical logo on a ball cap may take five minutes or so to stitch, roughly a dozen caps an hour.
The computer processes the artwork from your customer in a manner that the machine can understand. The computer allows you to do lettering with a design, such as adding the date to an event such as a golf tournament.
The process works like this:
1) The Computer chooses a design from the selection that you have stored on disk or your customer asks you to prepare his artwork for embroidery using the process known as "digitizing."
2) The computer program allows you to "input" the artwork so it can be seen on the color monitor.
3) Add lettering or dates, re-size the design to fit right on the garment or even edit the design for changes.
4) Once you save the design, it can be directly transferred to the machine for stitching. The computer has made intricate and complex embroidery available to the public on a scale never thought possible!
Commercial and Contract Embroidery Factories
Factories can have a few small machines or many large machines, or any combination of machines. Contract embroidery is a term used to describe embroidery being done on goods that are supplied by the customer to the embroidery house. Contract embroidery is limited to the trade. A company offering "Contract Embroidery" is embroidering wearable items for brokers, other embroiderers, ad specialty firms and screen printers at a wholesale rate. The customer of a contract embroiderer usually supplies the items to the factory and only pays the factory for the embroidery service. Commercial Embroiderers offer their services to the public and supply the wearable items.
Embroidery Machines
Not all machines are for embroidery only. Some are a combination of embroidery and sewing. Some of the more advanced features becoming available include a large color touchscreen, a USB interface, design editing software on the machine, embroidery adviser software, and design file storage systems. Commercial embroidery machines can be purchased as 1, 2, 4, 6, 12, 15, and 18 head machines. Industrial embroidery machines are available from 12 to 56 head models.
Loading the Embroidery Design and Stabilizing the Fabric, Embroidering the Design
Loading the Design
After editing the final design, the design file is loaded into the embroidery machine. Different machines expect different files formats. The most common home design format is PES. Common design file formats for the home and hobby market include: ART, PES, VIP, JEF, SEW, and HUS. Embroidery patterns can be transferred to the computerized embroidery machines in a variety of ways, either through cables, CDs, floppy disks, USB interfaces, or special cards that resemble flash and compact cards.
Stabilizing the Fabric
To prevent wrinkles and other problems, the fabric must be stabilized. The method of stabilizing depends to a large degree on the type of machine, the fabric type, and the design density. For example, knits and large designs typically require firm stabilization. There are many methods for stabilizing fabric, but most often one or more additional pieces of material called "stabilizers" or "interfacing" are added beneath and/or on top of the fabric. Many types of stabilizers exist, including cut-away, tear-away, vinyl, nylon, water-soluble, heat-n-gone, adhesive, open mesh, and combinations of these.
For smaller embroidered items, the item to be embroidered is hooped, and the hoop is attached to the machine. There is a mechanism on the machine (usually called an arm) that then moves the hoop under the needle.
For large commercially embroidered items, a bolt of fabric can be worked by a long row of embroidery "heads", producing a continuous pattern of embroidery. Each embroidery head is a sewing machine with multiple needles for different colors, and is usually capable of producing many special fabric effects including satin-stitch embroidery, chain-stitch embroidery, sequins, appliqué, cutwork, and other effects.
Embroidering the Design
Finally, the embroidery machine is started and monitored. For commercial machines, this process is a lot more automated than for the home embroiderer. For most designs, there is more than one color, and often additional processing for appliqués, foam, and other special effects. Since home machines only have one needle, every color change requires the user to cut the thread and change the color manually. In addition, most designs will have a few or many jumps that need to be cut. Depending on the quality and size of the design, stitching out a design file can require a few minutes or an hour or more.
After editing the final design, the design file is loaded into the embroidery machine. Different machines expect different files formats. The most common home design format is PES. Common design file formats for the home and hobby market include: ART, PES, VIP, JEF, SEW, and HUS. Embroidery patterns can be transferred to the computerized embroidery machines in a variety of ways, either through cables, CDs, floppy disks, USB interfaces, or special cards that resemble flash and compact cards.
Stabilizing the Fabric
To prevent wrinkles and other problems, the fabric must be stabilized. The method of stabilizing depends to a large degree on the type of machine, the fabric type, and the design density. For example, knits and large designs typically require firm stabilization. There are many methods for stabilizing fabric, but most often one or more additional pieces of material called "stabilizers" or "interfacing" are added beneath and/or on top of the fabric. Many types of stabilizers exist, including cut-away, tear-away, vinyl, nylon, water-soluble, heat-n-gone, adhesive, open mesh, and combinations of these.
For smaller embroidered items, the item to be embroidered is hooped, and the hoop is attached to the machine. There is a mechanism on the machine (usually called an arm) that then moves the hoop under the needle.
For large commercially embroidered items, a bolt of fabric can be worked by a long row of embroidery "heads", producing a continuous pattern of embroidery. Each embroidery head is a sewing machine with multiple needles for different colors, and is usually capable of producing many special fabric effects including satin-stitch embroidery, chain-stitch embroidery, sequins, appliqué, cutwork, and other effects.
Embroidering the Design
Finally, the embroidery machine is started and monitored. For commercial machines, this process is a lot more automated than for the home embroiderer. For most designs, there is more than one color, and often additional processing for appliqués, foam, and other special effects. Since home machines only have one needle, every color change requires the user to cut the thread and change the color manually. In addition, most designs will have a few or many jumps that need to be cut. Depending on the quality and size of the design, stitching out a design file can require a few minutes or an hour or more.
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