Home > Coatings > The Textiles Foam Lamination Machine Process for Beginners

custom foam fabricatorsReady to learn about laminating fabrics? We know, it’s not the most exciting topic on paper. But Conversion Technologies International has everything you need to know, from what makes a textiles foam lamination machine work to how outsourcing can simplify the process. Let’s dive in!

 

 

 

What is a lamination machine called?

A laminator machine has a pretty straightforward title—it’s a laminator. The question is less what the machine is called, and more whatever type of laminator you’re working with. A textiles foam lamination machine is going to function quite differently from a pouch lamination machine, for example.

How does a textiles foam lamination machine work?

Let’s get into the textile lamination process. Laminating fabrics functions differently from other lamination techniques, and is highly dependent on adhesives, among other things. Essentially, fabric lamination bonds two different materials together—in this case, involving fabrics. The final product is a composite material. Ideally, it’s stronger than either of the raw materials. Usually, we use industrial laminating to make fabrics more waterproof and durable, while maintaining or enhancing breathability. You’re getting the best of both worlds. The product still has integrity as a fabric; it simply functions better on an industrial level.

How many types of fabric lamination exist?

There are two main types of fabric lamination:

Flame fabric lamination. This technique sounds complicated—but it’s exactly where a textiles foam lamination machine comes into play. We use a flame to melt the foam. The foam then becomes an adhesive, attaching the substrate to the other material. We always use open cell foams for this particular process, though an alternative utilizes an adhesive combined with a release liner.

In that case, we apply the adhesive to both materials, and the release liner protects the adhesive layer until it’s time to bond it to the other. Once adhesion begins, we remove the release liner.

Hot melt fabric lamination. With regards to hot melt fabric lamination, we actually use a thermoplastic hot melt adhesive. We heat this adhesive before applying it across the desired surface with rollers. The rollers ensure an even distribution, avoiding lumps, bumps, and wrinkles within the final product. After that point, we feed the material through a compression device to achieve bonding. Hot melt laminating machines essentially force the materials together to finalize the lamination, and there you have it!

How many types of lamination machines exist?

Although you’ll encounter two main types of fabric lamination processes, there are three main industrial laminating machines available. These feature:

UV laminating machines. With this machine, we apply a liquid UV coating to printed material. After application, this liquid dries very quickly, hardening in the process. That creates the protective layer you usually want from lamination, while also preserving the overall quality of the material. This occurs as the material passes through the laminating machine—you could call it “curing”. Typically speaking, we don’t use this process for textiles, but it remains one of the more popular options for products like brochures. The drawbacks of this machine are that they tend to be more difficult to operate and clean, causing a lack of efficiency.

Pouch laminating machines. Ultimately, these laminating machines rely on thermal processes. The pouches in question contain glue, which melts as we expose the pouches to heat. The laminating machines then seal the product together by fusing the pouch. This creates the desired lamination, protecting the surface while brightening it at the same time. We sometimes refer to this process as encapsulation.

Film laminating machines. Film laminators really fall under the category of “roll laminators”—that is to say, machines that utilize rollers. We can use single or double sided laminators in this case, as well as wide format laminators. One of the great things about this approach is the degree of flexibility we have. This makes it easier for us to get the desired effect, regardless of the material or the order.

Can I outsource my lamination needs?

Yes, you can outsource your lamination needs—and your manufacturing needs in general. While outsourcing to a third party manufacturer isn’t for everyone, it can certainly work for some. Some business owners choose to outsource to accommodate growth. It’s a good problem to have, but not every business can or should handle scaling up in-house.

Some of the benefits of outsourcing include:

Affordability. If you don’t outsource, you must directly maintain the required facilities, tools, and employees. When you outsource, the third party covers these factors for you. In most cases, this allows you to save money.

Efficiency. If you’re less than experienced with a process like lamination, you’ll often need to put up with some trial and error. When you’re scaling up, this slowed down process simply isn’t ideal. An experienced manufacturer will get the results you need faster, and with much less stress.

Consistency. The reality is that newer, less experienced business owners tend to encounter more inconsistencies with new processes. Third party manufacturers have processes like lamination down to a science. You’re not wasting time, you’re not wasting money, and you’re much less likely to encounter mistakes in the final product.

Ready to take the next step and learn more about lamination from the experts? Call CTI at 419-924-5566 or contact us here. We’ll walk you through this process—and how a third party manufacturing company can simplify it.