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Flagmakers offers a range of construction methods, and will advise on the best method or combination of methods to suit your requirements.

Dye screen printed flags

For quantities of 10  or more, Dye Screen Printing is often the most economical and effective method of construction.

The flag fabric is screen printed with dyes, which are then heat activated,  and completely penetrate the fabric fibres in a process called “dye sublimation”.  The colour range is very comprehensive (refer to colour data sheet), and the results are excellent.  Colour penetration ensures flags look equally as bright on both sides, with good definition and a crisp, bright appearance. The image on the back of the flag appears in ‘mirror’ reverse.

As with all screen-printing processes, initial preparation costs are relatively high as individual screens and colour separations are required for each colour.  Once the preparatory work is completed however, the printing process itself is comparatively rapid, and for this reason, dye screen printed flag prices become more attractive as quantities increase.  Conversely, prices increase as the numbers of colours per flag increases (excluding white).

Flagmakers prices for initial orders of screen printed flags include all preparatory costs (assuming good quality initial art is supplied), and reduced "repeat prices" can often be applied to subsequent orders

Using photographic images with dye screen printing.

The appeal of flags and banners is due primarily to their colour and movement.  Most designs are bright and bold, and utilise "solid" (or "spot") colours, including virtually all national flags, and most corporate flags and banners.  Dye screen printing is ideal for reproducing these designs as dye colours are mixed to match as closely as possible the particular colours or shades required.

Flags and banners with particularly complex designs, or those incorporating photographic images (or shading and colour gradients) can also be successfully dye screen printed.  Special film-work to enable the dyes to be printed in "dot" or "screen" form (rather than as solid colours) will be required however, and this will add to the cost of the initial job.

Because the dyes are required to penetrate (or "bleed") right through the fabric to create an image on the front and reverse sides, they will also bleed slightly sideways.  For this reason, the "dots" required to reproduce the image need to be relatively large and widely spaced to ensure they do not join together during printing.  As a result, a low or coarse resolution screen of around 20 - dip is necessary, producing an image with a relatively "grainy" appearance when viewed closely, and being hand printed, minor variations may exist between each flag  or banner.

Where colours and tones are to be produced by a mixture of  coloured dots (e.g. using "CMYK" or "process" colours), precise colour matching (to PMS colours for example) may not always be achievable.  This is especially true for  large monotone areas, and to achieve a better result additional special "solid colours" may have to be printed. Stand back however, and the final result will be fantastic!

Please ask to see our separate "Process Colour" datasheet, and ensure any critical areas of your design are discussed with us prior to production.

Fine Detail

Because dyes are required to penetrate (or ‘bleed’) right through the fabric to create a bold image on both sides (a ‘mirror’ image appears on the reverse), they will also bleed slightly sideways. As a result, lines less than 3mm wide may close up and very small text or fine detail can be lost. If this is important, fine detail should be avoided, ‘fattened’ or enlarged. Please check.

When fine detail is essential our digital printing process may be more suitable - see below.

Fully sewn flags

This traditional method of construction involves the use of pre-dyed fabrics being appliqued (sewn) together to form the flag design.

This method calls for skilled machinists who craft the flag from a comprehensive range of standard fabric colours, resulting in a durable and attractive product.

Sewn flags are usually heavier than printed flags due to multiple layers of fabric often being used to form the design.  The image on the back of the flag appears in ‘mirror’ reverse.

Fully sewn flags are the choice of flag traditionalists - you can see the work and skill that goes into the construction of the flag.

The fully sewn manufacturing method also allows us to make large flags that other methods don’t accommodate - up to 15m long.

Digitally printed fabric flags.

For flags and fabric banners requiring colour photographic images, very detailed line art and other complex graphics, 'dye sublimation' or direct to fabric digital printing is an impressive option. It enables the reproduction of high-resolution artwork and is economical for small runs.

It is ideally suited to producing banners, especially for indoor use where high quality fabric signage is unbeatable. 

Flagmakers Polyknit, Polybunting or Ice Satin fabrics can be used, and these are printed in Single Sided, Colour-through and Double Sided print qualities., depending on the product.
Flagmakers dye sublimation digitally printed flags and banners are made on expensive, highly sophisticated and up to date equipment, operated by skilled technicians. The results have won several printing awards for quality, and are among the best available anywhere in the world.

Despite its sophistication,digital printing is not without its limitations however, and it is important to understand and acknowledge these.  Please refer to the following and feel free to discuss any details further with Flagmakers.

All colours and tones are produced by a mixture of four dye colours (or sometimes 6), printed in small dots.  These four "process" colours are cyan, magenta, yellow and black, or "CMYK" (our products are actually printed with both standard and light shades of CMYK to provide superior results). However, precise colour matching (to PMS colours for example) is not always possible.

Computer software and hardware tends to interpret colour information differently, and shades will vary slightly when viewed on different monitors or when printed by different printers etc.  They may also differ when digitally printed onto fabric or other substrates, as this creates more variables.  Printing onto different types of fabric may also provide slightly different results.

When colour files are supplied in CMYK format we must use them ‘as is’.  We cannot adjust colour levels during the printing process (to counter individual colour variances, for example) as any adjustment will effect the total image.

Tests show that our digitally printed flags and banners perform well when used for exterior use, but like all coloured fabrics, some fading will be inevitable, and some colours/shades will fade more rapidly than others. This can ultimately result in colours becoming less intense, and/or an alteration in the shades. Consequently, as this process can produce literally hundreds of thousands of different shades, colour fastness cannot be accurately predicted.

Award Winning Quality

Award winning print quality - Flagmakers digital and dye screen printing has won many Pride in Print Awards for its quality.

Easy Care

Flagmakers PVC banners will not tear or crease permanently like other banner materials and is water resistant, washable, light weight and compact. Perfect for storage or transportation.

Versatile

PVC banners can be made any size or shape. We also offer an extensive range of high quality and innovative display methods to ensure your banners are displayed to their full advantage in all situations

Flagmakers reinforced PVC digitally printed banners are an ideal choice where heavy duty or large format signage is required. The design is reproduced directly from a digital computer file, and is printed directly onto the PVC fabric using commercial large format inkjet printers.

This method utilises leading edge technology, and is ideally suited to producing stunning banners for both indoor and outdoor use. PVC fabrics available range from light to heavy weight including blockout PVC.

For larger quantities we also offer screen printing. It is our aim to provide the best possible product, at the best price, supplied to you when you need it.