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Fusing: By: Ashutosh Kumar Ashutosh Vatsa Kr. Pramendra Sinha S.K. Pegu

Fusing is the process of attaching an interlining like a woven, knitted, or non-woven material to parts of a garment that require stiffness or shape retention. It involves applying a thermoplastic resin coating to a base cloth or interlining material. When heat and pressure are applied, the resin melts and fuses the base cloth to the interlining. Different methods like flat bed pressing, continuous pressing, or high frequency fusing are used to fuse the materials together. Key factors in fusing include temperature, time, pressure, and the type of resin used depending on the base materials and desired properties. Quality control measures ensure an effective bond and performance of the fused components.

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108 views

Fusing: By: Ashutosh Kumar Ashutosh Vatsa Kr. Pramendra Sinha S.K. Pegu

Fusing is the process of attaching an interlining like a woven, knitted, or non-woven material to parts of a garment that require stiffness or shape retention. It involves applying a thermoplastic resin coating to a base cloth or interlining material. When heat and pressure are applied, the resin melts and fuses the base cloth to the interlining. Different methods like flat bed pressing, continuous pressing, or high frequency fusing are used to fuse the materials together. Key factors in fusing include temperature, time, pressure, and the type of resin used depending on the base materials and desired properties. Quality control measures ensure an effective bond and performance of the fused components.

Uploaded by

Shreya Agarwal
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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FUSING

By: Ashutosh Kumar Ashutosh vatsa Kr. Pramendra Sinha S.k. Pegu

What is Fusing?
It is a process of attaching an interlining, especially to the part of a garment that requires stiffness. Some of the application area of Fusing in a garment are placket, collar, cuff, waistband, men's jacket forefront, etc.

Requirements for Fusing


Base Cloth
Interlining

Coating System

Resins

Base Clothes (Substrate)


It is an interlining material onto which the thermoplastic resin is coated, sprayed or printed. Properties of Garment influenced: Handle and Bulk Shape Retention Shrinkage Control Crease Recovery Appearance Durability

Types:

Woven

Knitted

Non-woven

Types of Interlining
Woven Produced from animal hair, viscose, cotton, polyester or acrylic fiber. Maximum control on shrinkage and shape retention. Varying properties in warp and weft direction. Knitted Produced from Polyester, polyamide, acrylic and viscose fiber. Elasticity to the fused Components. Soft and lofty handle. Non-woven Originated from paper industry. Mixture of fiber held together at bond sites. Factors affecting end performance: fiber, web formation, bonding.

Knitted Interlining

Woven Interlining

Non-Woven Interlining

Non woven Interlining


Extensively used in Industry. Properties could be modified as per end uses. Fibers: mostly Synthetic fiber like viscose, nylon, polyester or acrylic is used. Web Formation: orientation of fiber in substrate
Dry laid web formation Wet laid web formation Spun bonded webs

Bonding: locking of fiber together.


Mechanical bonding Chemical bonding

Resins
The material applied to base cloth and when subjected to heat and pressure, they become the sole bonding agent between Top cloth and Interlining. Thermoplasticity, change with heat, is the basis of fusible interlinings. In cold state, it is not adhesive, when subjected to heat and pressure, melts and creates a bond.

Factors affecting suitability of Resins:


Upper limit temperature
generally not more than 1750c, should not damage top cloth

Lower limit temperature


generally not less than 1100c, to ensure adequacy of bonding

Cleanability
To withstand the washing and cleaning throughout life of garment

Thermoplasticity
Change in heat and pressure is sufficient enough to form a bond with top cloth

Handle
Should contribute to desire handle of final laminate

Safety
Harmless in processing and end-use

Types of Resins
Polyethylene : used for wash and wear garments, washable and Dry-cleanable. Polyamide : Dry-cleanable. Polyester : Cheaper, wide range of fusing temperature (650-1200C). PVC : used for siliconized rainwear fabric, requires softening with plasticizers. Resin Blends : used for specific purposes, blend of above mentioned maerial.

Distribution of Resin
Inadequate bonding (incorrect) Strike through and strike Back (incorrect) Correct bonding with good Penetration of Adhesive (correct)

Components of Fusing

Temperature

Time
Cooling

Pressure

Temp. is 13001600C, Use of applied electroTemp. mechani should cal in be timing the devices range of to 50C measur Too e time high Time Temp. applied could depend Reduc cause s upon es the strike type latent through and tempera or strike nature ture backto of resin, 300C Used substrat Use of to e, top water establis cloth cooled h an and plates, intimate fusing aircontact equipm circulati between ents. on, to-cloth vacuum. and fusible. Applie d via

Fusing Methods
Single Fusing
Fusible positioned on the top of the Cloth

Reverse Fusing
Cloth is Positioned on the top of Fusible

Sandwich Fusing
Fusing 2 components in 1 operation Cloth on the outside, 2 fusible in the middle

Double Fusing
Fusing 2 fusible positioned one on the top of other, to the top cloth in 1 operation

Top Fusing
Fusible components are positioned on the top of the cloth and heat I applied directly to the top cloth

Coating System
The process in which thermoplastic resin is deposited or secured onto the substrate material. It involves the application of carefully selected Particle size fraction of Particular resin being used.

Coating Methods:
Scatter coating:
o o o o o o

largest particle size 150 to 400 microns Specifically designed scattering heads provides scatter under automatic control Resin is softened in an oven Pressed on base cloth and cooled Cheapest method Product is not uniform and flexible

Coating Methods (Contd):


Dry dot printed coating:
Powdered resin fills engraved holes on the roller Base cloth passed over heated roller Then against engraved rollers The powdered resin adheres to cloth in from of dots Followed by oven heating for permanent adhesion Temp and pressure of rollers depends on resin types Pattern : 3 12 dots /cm Light weight fabric - small dot high concentration Heavy weight fabric large dot small concentration

Coating Methods (Contd):


Paste coating:
o o o o o o

Resin powder blended with water or other agents to form smooth paste Printed on base cloth Heat removes water Gives precisely shaped dots ANUSHA Gives fine dots Used in shirt colour fusible

Performed system Extrusion laminating Emulsion laminating

Defects in fusing Process:

Fusing Equipments

Flat Bed Press

Continuous Fusing Machine

Hand Iron

Steam Press

High Frequency Fusing

Flat Bed Press


Padded top and Bottom bucks Heating Element in 1 or both bucks Bottom Buck Static, Top buck can be moved vertically Option of Single tray and Twin tray systems Low Productivity The three processes are Loading, Fusing and Cooling.

Flat Bed Press

Continuous Fusing Press


Use of Conveyor Belt as a mean of transport Synchronized belt speed Heating plates, cylinder, rollers, and heating zones are used Rubber covered steel rollers to apply pressure Air cooling and water cooling systems Take off could be done manually or mechanically

Continuous Fusing Press

High Frequency Fusing


Multiple plies are stacked up (up to 70 mm height) and fused simultaneously High Productivity Heat from high frequency energy No shrinkage or color change Dielectric heat: plates generate high frequency field, heat effect is distributed uniformly in length ,width and full height between platen

High Frequency Fusing


Heating effect is different for different polymers Adhesive is heated up faster than fabric or interlining Time depend on capacity of High Frequency unit and weight of load to be fused
o

E.g.; 30 Kw unit ; load 5-20 kg : 1-3 min

Disadvantage: the press needs to be set for fusing materials on basis of fibre, content, weight thickness and moisture content

High Frequency Fusing

Manufacturers:
Shanghai Dahe New Material Technology Co., Ltd Rocmachine Co., Ltd. Tianjin Tian-Yin Machinery And Electron Co., Ltd.

Quality Control
Temperature Test papers : reacts by changing color. Pyrometers : high accuracy, rapid response, costly. Stop watch: High accuracy. Peel strength Test Dry-clean and wash Test.

Control System

Thank you
Bibliography:
o o o o

Fusing Technology by Gerry Cooklin www.fusingpressindia.com machinery.fibre2fashion.com/7/fusing-machine www.apparelntextile.com/products_apparel_interlini ngs.html

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