Fabrication techniques that FilzFelt offers include:
Die cutting and CNC Precision Cutting
Die cutting and CNC precision cutting is the slicing of the felt with a blade.
Die cutting is produced with a pre-shaped die and is generally used to manufacture multiples of the same shape or design. It creates a crisp, clean cut and can produce identical multiples quickly and easily. Costs and lead times are affected by the production of the custom die board as well as the labor and material cost of each piece.
CNC precision cutting is computer-controlled cutting for large scale pieces. This extremely accurate and efficient mechanical cutting is done on high precision machines with the use of CAD/CAM software. Cut-outs can be as small as 1/8 of an inch and the maximum width and length are determined by the size of the rolls.
Laser Cutting
Laser cutting is exactly what it sounds like: a computer-guided laser burns away a thin swath of felt thereby separating it. This technology allows for complicated and intricate designs, small-scale cutting and exceptionally smooth curves. Unlike mechanical cutting, since wool felt is a natural material (sheep’s hair) the wool is burned in the process leaving a discoloration at the edge and a slight smell. Many designers use this quality to enhance the look of their work and the smell dissipates over time or can be removed by dry cleaning.
Adhesive Backing
Our felt can be adhered to vertical or horizontal surfaces with adhesive applied in the field however we also offer mill-applied adhesives. Available in a 35" width, the minimum for this application is 22 linear yards (20 linear meters) and we offer a permanent or removable adhesive to suit every project need.
Custom Lamination
FilzFelt carries 3mm and 5mm bi-color laminated felt however we can also custom laminate the colors of your choice. The process of lamination fuses two sheets of felt together with heat and moisture and we require 218.72 linear yards (200 linear meters) minimum.
Sewing and Embroidering
FilzFelt can provide stitching and embroidery services for prototypes and finished custom products. Depending on individual project requirements, we offer sewing services both in-house and through our network of talented local stitchers. We take pride in each and every detail and stitch while listening closely to each client’s needs and concerns. Thorough quality control checks along each step of the project ensure that finished goods are impeccably stitched, professionally made and of the highest quality.
Finishing, Binding and Hand-Stitching
Specifically suited to flooring products, we can provide finishing, binding and hand-stitching services. Choices include stitching color, style and felt thickness and color. Contact us for stitching styles (whip, blanket, baseball, etc.) and for thread color selection and availability.
Screen-printing
Screen-printing on felt is a dynamic way to showcase your logo or graphic. The ink colors we provide are matched to the Pantone Matching System and we keep the environmental impact in mind by also offering eco-friendly options. Green printing utilizes non-phthalate, non-PVC plastisol screen-printing ink, specially formulated with the high quality and print application standards.
Prototyping
Unable to commit to our minimums? We can provide prototypes of manufactured products at a cost that fits your budget. Our one-time fee is added to material cost of the felt, manufacturing and shipping. And we can also offer design services to help you along the way!
Private Labeling
Love one of our products and want to make it your own? FilzFelt can customize any of our existing products with your choice of color, thickness and size. And you can add your logo or corporate sponsor name, etc. with tags, embroidery or screen-printing. Contact us about private label capabilities and pricing structures. We typically prefer a minimum of 100 to 200 pieces, but we’re flexible and eager to work with you and will evaluate on a project to project basis.