EMBROIDERY

Computerized machine embroidery

Here at Adrenaline Printing we use SWF commercial computerised embroidery machines and these days virtually all modern embroidery machines are computer controlled and specifically engineered for embroidery. Industrial/commercial embroidery machines and sewing/embroidery machines both have a hooping or framing system that holds the framed area of fabric tautly and securely underneath the sewing needle and move it around automatically to create a design from a digital embroidery file (pre-made pattern)

Both can read and sew out embroidery design files (of various types) with varying degrees of user input required depending on its capabilities and stitch up to 900 stitched per minute which is very fast and very acurate. The average price per 1000 ststches is $1-$1.50 depending on the amount od colours and trims needed in each edseign an dalso the number of garments to be embroidered. The more gramnet to be embroidered (ie 500 +) with less colour changes and trims can be as low as 80c per 1000 stitches

For example sewing-embroidery machines generally only having one needle will require the user to change thread colours "on the fly" where as we use the multi-needle (industrial) machines we use having more needles can be threaded up all at once prior to running the design. Our machiines can do up to 15 colour changes automaticaly. This does requires the user to input the correct colour (needle) change sequence into the machine beforehand. but thi sneeds to be done only once and then it si just the case of hooping the garment and running the maching whcih doed all the rest automatically and is very fast and very acurate.

 Our modern SWF (industrial) embroidery machines can trim and change colours automatically and can have anywhere up to 15 or more needles per "head"(available colours). The term "head" refers to the "sewing head" as some of the machines are 8 head industrial embroidery machines can sew the same design out onto 8 garments at once which is good for larger jobs. enabling us to embroider up to 350 garments per day.  Others are single head meaning they can only embroidery 1 item at a time which a good for smaller jobs of up to 50 -80 items per day 

The computerized machine embroidery process

These are the basic steps for creating embroidery with a computerized embroidery machine.

• purchase or create a digitized embroidery design file
• edit the design and/or combine with other designs (optional)
• load the final design file into the embroidery machine
• stabilize the fabric and place it in the machine
• start and monitor the embroidery machine

 Design files

Digitized embroidery design files can be either purchased or created (digitized) with industry specific embroidery digitizing software.

Embroidery file formats are many and varied and broadly fall into two categories: 

1. Source formats, Specific to the software used to create the design. (i.e. the original file the digitizer keeps for editing.)
2. Stitch formats, the machine file program which is codes for the machine to stitch out the design 

Editing designs

Once a design has been digitized, it can be edited or combined with other designs by software. With most embroidery software the user can rotate, scale, move, stretch, distort, split, crop, or duplicate the design in an endless pattern. Most software allows the user to add text quickly and easily. Often the colors of the design can be changed, made monochrome, or re-sorted. More sophisticated packages will allow the user to edit, add or remove individual stitches. For those without editing software, some embroidery machines have rudimentary design editing features built in.

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 the potential for additional processing for appliqués, foam, or 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.