OK, here is a new one for me and looking for a way to resolve. We embroidered some police shirts with their badge on a polo pique (5-11) shirt. The design has 23,486 stitches in a 4x5 area for the left chest. We did this same design on some other shirts in '07 and not a problem. On that sew out we use one 3.1 oz cut-a-way backing and solvi for the front. On this sew out we did the same design, backing and support but now they are "folding" on the shirts. When I say folding, they look good until the customer washes the shirt and then they fold or wrinkle inwards.
Since these shirts were done in stages we attempted to correct the folding with additional support so the second set of shirts were sewn with a sandwich of 3.1 cut-a-way, fiber mesh, and then another 3.1 cut-a-way. Solvi was used on the front again since it was a pique. But the problem has shown itself again.
Is there any way to add a fuseable backing or something else to prevent this from happening? The customer understands this problem but is not happy with the outcome., and neither are we.
23,000 stitches in a 4x5 area is pretty close to bullet proof. 5.11 shirts are great but do not always take embroidery very well. I would reduce the stitch density at least 10% and then look at the underlay to where you can reduce things a bit. Badge designs are also notorious for being stitch intensive.
23,000 stitches in a 4x5 area is pretty close to bullet proof. 5.11 shirts are great but do not always take embroidery very well. I would reduce the stitch density at least 10% and then look at the underlay to where you can reduce things a bit. Badge designs are also notorious for being stitch intensive.
The job has been completed and now the complaints are coming in...
Is there something that can be done after the product is complete. They look great when folded and delivered, but once worn they start to fold.
As the others said, you should reduce the stitch count. Perhaps even more than 10%. Was this a larger file and you just reduced it? Also if you can, try adding some pull compensation to the file, this might also help. If you can't reduce stitches I don't think any type of backing will help. Good luck!
You could try some iron on "Bemis Heat Seal" to the back of the Logo(inside of shirt). However it will make the Logo much Stiffer and could end up being uncomfortable. Bemis is a Madiera Product. Google it to find suppliers and more info. I use it on Badges.
Were the other shirts that you did in 07 woven or of the same material ?
Ideally, I would have the design re-digitized making sure the digitizer is reducing underlay and the design density.
We do just about all the police and sheriff's department shirts in the area. Just about all are on the 5-11 shirts. The only thing you can do is reduce the thread count.
Were the other shirts that you did in 07 woven or of the same material ?
Ideally, I would have the design re-digitized making sure the digitizer is reducing underlay and the design density.
The other shirts from '07 were the exact same shirts with the exact same design that's why we thought the '08 shirts would not be a problem. We completed the first 50 in January and the last 50 in Feb. It looks like the problem was there on the January shirts, but more noticeable on the Feb shirts. Since the design is done, and the customer has accepted the delivery I guess we are looking at the Maderia product.
Buzzard,
Any difference in the hooping method or the person doing it ? Possibly the material is being pulled too tight, just the slightest and too much tension and it could affect the design.
I did go back and check a design I do for the FLW/TBF fishing tour and that design is 23K stitiches with heavy underlay. Got this from the FLW, and I haven't had a problem with it on woven shirts and microfiber jackets. I have to go back and see if I did any on a knit shirt.
After embroidery 
, and neither are we.
