Technology
Our state of the art studio is equipped with the latest in technology. This enables us to keep in lock-step with the industry's leading manufacturers' capabilities. Wookey Design Studio keeps track of the latest automated machinery and techniques that save you time and money in production. Our access to technology gives you the competitive edge and sets your product above and beyond your competition.
Hot-air Welding
Hot air can be used to tape seams, join layers of fabric, and laminate elements to fabric. This technique is one of the fastest growing areas of new technology and is used to create products that are "stitchless". This is also the primary method by which seam tape is laminated to a seam to make the seam waterproof.
RF Welding
Radio frequency or RF welding is used to create water and airtight seams in polyester and PVC backed materials. A radio frequency sound wave is passed through the material to be joined, and heats the fabric, thus bonding it. This is the technique used to make most commercial dry bags and rubber rafts, but can also be used to attach plastic pieces and webbing to material.
Ultrasonic Welding
Similar to RF welding, ultrasonic welding joins fabric using ultrasonic vibrations. These vibrations heat the fabric through a die. The combination of heat and pressure permanently join the layers of fabric together.
Dye Sublimation
Dye sublimation is a technique that can add graphic elements to fabric and is used for logos, care instructions, size information and artwork. The dye sublimation process differs from screen-printing and heat transfers by printing into the fabric rather than on it. The dye turns into a gas and becomes integrated in to the very fibers of the fabric, ensuring that your graphic element will never fade due to UV saturation, wear, or washing.
Die and Laser Cutting
Die and Laser cutting is used when you have a complicated shape that needs to be cut precisely. Or when the shapes that need to be cut have a complicated nesting pattern to get the best material utilization. It can also be used to speed up manufacturing by stamping out many layers of a nested shape at a time.
Die cutting uses a steel rule die on a large hydraulic press to stamp a shape out of foam, plastic, neoprene or the like. Laser cutting is utilized when the materials are not good for die cutting, or when the shapes are too complex to use a steel rule die.
Advanced Glues
Advanced glues are being used more frequently in the textile industry to create the stitchless look or in applications where sewing is not applicable or possible. Glues are also used where the fabric is too gossamer, or is not of the right composition to be used with hot air, RF or Ultrasonic techniques.
Thermal Molding and Compression Molding
Thermally molded back panels, hip belts and carrying cases are becoming more and more prevalent in the marketplace as companies look to add comfort, air flow and that "cool" thermal molded look. By thermal molding foam, we can create air channels, recessed areas and comfort zones that are formed to the anatomical shape of ones body. The foam is first laminated to a face fabric and then heated in an oven. The composite layer is then pressed with a die that shapes the foam and cuts the shape out like a die cutter. The result is always impressive.
Advanced Sewing Techniques
One of the many advantages to our integrated vertical design process is that we are not only excellent designers, we are also impeccable sewers and seamstresses with 11 years experience. It is entirely possible to design a product that cannot be sewn. That is to say, our experience with durable sewn goods enhances our design process. By applying our advanced sewing techniques, Wookey Design Studio is able to create products that streamline the manufacturing process, saving you time and money in production.