A woven patch is made by using a jacquard loom to interlace threads, typically polyester or cotton, creating the desired design directly into the fabric.
Here's a more detailed breakdown of the process:
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Design Preparation: The design is digitized and converted into a format that the jacquard loom can understand. This involves specifying the colors, thread types, and weaving patterns.
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Jacquard Loom Setup: The jacquard loom is set up with spools of thread in the appropriate colors. These looms are capable of individually controlling each warp thread, allowing for incredibly intricate designs.
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Weaving Process:
- The jacquard loom weaves the design by interlacing the warp (lengthwise) and weft (crosswise) threads.
- The digitized design controls which warp threads are raised or lowered for each pass of the weft thread, precisely creating the pattern.
- Because the design is woven directly into the fabric, woven patches boast a high level of detail and durability compared to embroidered patches.
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Finishing Touches: After the weaving process, the patch material is removed from the loom. Individual patches are then cut from the larger woven piece. Edges may be serged, merrowed (overlocked), or heat-cut to prevent fraying. Backing materials, such as iron-on adhesive or hook-and-loop fastener (Velcro), can be applied.
Key Advantages of Woven Patches:
- High Detail: Capable of reproducing fine lines and small details that embroidery struggles with.
- Durability: The woven construction creates a strong and long-lasting patch.
- Smooth Surface: Unlike embroidered patches, woven patches have a smooth, flat surface.
In summary, the production of a woven patch utilizes a jacquard loom to weave intricate designs with polyester or cotton threads, creating a durable and highly detailed emblem.
