How are Flags Created?
How are our flags created? At The Custom Windsock Co., we are passionate about our products. We strive to source the best fabric and we take great pride in our process. All of our U.S. and State flags are made with care in the United States, supporting the American economy.
Our nylon is sourced from an American company. The nylon yarn is woven by a mill and then shipped to our manufacturing facility. It is tagged and separated based on the printing process it will undergo. Our nylon is UV coated to help it resist fading.
US and State flags are sent to our screen printing area. Screen printing is a method of printing an image on fabric by forcing ink onto the nylon surface through a prepared screen of fine material so a pattern is created. This method allows us to force more ink into the material, creating a more saturated material than with other forms of printing. This allows our flags to be durable and remain resistant to fading longer than others.
Once a flag’s graphic is printed onto the nylon, whether screen printed or digitally printed, the nylon undergoes a curing process. All of our nylon flags are steamed under pressure after being printed to impregnate the ink within the fabric. This process can take anywhere from 45 min to over an hour depending on the size and colours of the flags. Once the flags have been cured, the richness of the colours comes through.
Our flags then move from the curing phase to the washing phase. All nylon flags are washed thoroughly to remove residual ink.
The flag then moves from our curing department to our finishing department where employees sew the flags. Our flags are quadruple stitched at the fly end to ensure we minimize wear and tear from wind damage. We also Color-match the thread as far as possible. We also use a special woolen white polyester header for the flag as opposed to just sewing in a nylon header so that the flag is reinforced at the header creating a sturdier product. We then sew in either grommets or create a header with a built in sleeve as per the customer’s request.
This multi-step process to create a flag for you occurs in the United States, made by Americans for Americans.