Flag & Banner Fabric Printing Processes

Silk Screened Banner Flags

Flags are printed using large format automated silk screen printing machines. These printing machines allow us to produce each flag accurately and quickly, but due to the lengthy setup process we require a minimum order of 10 flags. Silkscreening is a good choice for simple vector graphics made up of mostly shapes and/or few colors required.

Next the flags are heat treated. This is done not only to make the images look better but also to fix the inks against harsh weather, making them last longer. The inks permeate through the fabric, creating almost 100% coverage on the reverse side.

Five successive washing cycles brings out the final brightness of the flags and softens the cloth. Oven drying guarantees size stability of the flags. The flags are trimmed and hemmed before a reinforcing strip is applied to the top and one side of the flags. The grommets are then inserted and the flags are packed up for shipment.

Digitally Printed Banner Flags

You custom artwork can be printed digitally on a large format inkjet printer. A big advantage to choosing a digitally printed flag is there are no minimum order requirements (unlike the silkscreen process). Whether you want 1 or 21 flags, you have the freedom to choose any quantity. Digital printing can print photographs and fine details too, providing more options when selecting your flag. However, a digitally printed flag does not offer the same ink penetration as does silk-screening, so your flag will look noticeably lighter on the reverse side. This can be fixed by purchasing a double-sided flag if necessary: Two digitally printed flags are sewn back to back, providing the same density of color.

The flags then go through a series of baths from cold to hot water and dried.The flags are trimmed and hemmed before a reinforcing strip is applied to the top and one side of the flags. The grommets are then inserted and the flags are packed up for shipment.

Dye Sublimated Printed Banner Flags

Flags printed with the dye sublimation process combine the best of both worlds. You get the richness in color from silkscreening with the photographic abilities of digital printing. Your artwork is initially printed onto transfer paper with the reverse image of your final graphic. Then, the image is transferred with a heat press onto polyester fabric at temperatures hitting 375 F°. While the fabric is heated under this high temperature and pressure, the dyes turn into gases which permeate and solidify into the flag's fibers. The design is now permanently fixed so it can be washed without risk of damaging the image's quality.

There are no minimum ordering requirements for dye sublimated flags, but the reverse side will display about 15% lighter. We offer 8 day lead times for dye sub flags, so if you're under the gun and need a custom-printed flag fast, we can help!


Important information about choosing a custom flag.

One of the most important reasons for purchasing a banner flag is the advertising "effect" that wind motion has on the flag. A subtle "wave motion" blowing through your banner flag is both aesthetically appealing and attracts attention. To epitomize this point there is a new indoor banner pole on the market in Europe that has a fan in the base to blows a subtle breeze through the banner flag.Our flags are printed on knitted polyester fabric designed specifically for flags.

  • This banner fabric has a nice "wave motion" in the wind.
  • The knitted polyester was designed to last longer than nylon flags.
  • This banner fabric cannot tear or shred like many other fabrics do in the wind.
  • Wrinkles are not noticeable at normal viewing distances. Creases from folding can be ironed out if desired.

Know what material your banner flag is being printed on!

Beware of flags printed on vinyl or other heavy weight materials! We love digitally printed vinyl for banner stands, it is a very good material for this purpose, but it was Not designed for flags.

  • Vinyl is a heavy material (even 10oz vinyl)
  • It does not wave well in the wind
  • Its weight of the flag causes the support arm to sag
  • Creases and wrinkles are more noticeable even at normal viewing distances and cannot be easily removed
  • Vinly for printing white on the back and does not allow for any through print. An image much be applied to the backside of the flag.

Our Vinyl Story:

Before coming to market with our GiantPole and TriPole products, we ordered some sample flags from various vendors. Two of the samples were printed on vinyl:

The first was printed on both sides of the vinyl material. A very popular 12oz vinyl banner material was used and it was printed on a solvent based inkjet printer. This flag hangs like a rigid sheet of material and causes the support arm to sag. It does not blow in light winds and does not create nearly as much motion as the fabric flags we received.

The second vinyl flag was comprised of two pieces of vinyl taped back to back. While this is similar to how we sew two flags together, the edges were left unfinished. When rolled, the wrinkles and creases were formed along the entire length of the flag. This flag was twice as heavy as the first vinyl flag so it barely moved in anything but a strong wind and caused the support arm to sag a great deal. We do not recommend this method to anyone. The flags are too heavy for the system and look horrible.

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