Southeast University

Department of Textile Engineering

Assignment

Course code: TEX227.2.

Course Title: Garments Mfg. Technology-I.
Experiment Title: What is Fabric Fusing Machines. Types of fusing
machines and how do they Work?
Submitted To: Israt Ansari, Lecturer, Initial: IZA.
Department of textile Engineering
Southeast University
Submitted by,
Name: Akon Rakibuzzaman Tamal.
ID: 2023100410031
Batch: 17.
Section: A.
Date of submission: 25-10-2024.
 What is Fabric Fusing Machines. Types of fusing machines and how do they
Work?

Fabric fusing is an important part of the garment production process. It involves

attaching an interlining between parts of the garment fabric for increased strength and
shape retention.

What is Fabric Fusing Machine?

During fabric fusing, an adhesive resin is applied to one side of the interlining, and then
bonded to another piece of fabric by applying heat and pressure. The resin solidifies as
it cools, strengthening the bond between the two parts. The fusing process replaces the
traditional method of sewing fabric parts and interlinings together for most fabric types.

Why Fabric Fusing Machines are Indispensable.

Fabric fusing machines are important in garment production for their ability to boost
productivity. They provide a consistent and efficient means of bonding fabric, essential
for industries ranging from fashion to automotive. These machines are specifically
designed to apply the exact amount of heat and pressure needed to melt the adhesive
resin, ensuring a strong bond without compromising the fabric quality.

Operational Principles of Fabric Fusing Machines

Fabric fusing is most effective when temperature, pressure, and processing time are
precisely controlled. To start with, the fabric is laid flat, and the machine is preheated to
a specified temperature to avoid shrinkage. The resin-coated interlining is then placed
onto the fabric, and the combination is fed into the fusing machine. Then, they are
heated and pressed together under predetermined conditions before being set aside to
cool, solidifying the adhesive.

Types of Fabric Fusing Techniques

Reverse Fusing: This process is best for little fabric pieces, as it involves placing the
interlining resin-side up with the fabric laid over it.

Sandwich Fusing: This technology, which is suitable for continuous fusing machines,
fuses four layers together while carefully adjusting heat and pressure.

Double Fusing: Used for clothes that require additional structure, such as jackets and
collars, this procedure fuses two types of interlining with fabric, necessitating exact
management to eliminate errors.

Understanding Fabric Fusing Defects

Improper temperature and pressure management can lead to defects like strike back
and strike through, where the resin seeps through the fabric. These defects underscore
the importance of precise control during the fusing process.

Understanding Fabric Fusing Defects

One of the primary challenges in the fabric fusing process is managing the temperature
and pressure applied to ensure a strong and even bond without compromising the
fabric's quality. Incorrectly controlled conditions can lead to two specific types of fusing
defects, namely "strike back" and "strike through." These defects involve the unintended
migration of adhesive resin through the fabric and interlining layers, potentially
degrading the garment's quality and appearance.

Strike Back: This defect manifests when the resin applied to the interlining permeates
through to the back side of the fabric. It is often the result of applying more heat and
pressure than necessary, causing the resin to move beyond the interlining and adhere
to the back side of the fabric. This can alter the fabric's appearance and texture,
possibly affecting the garment's durability and overall wear.

Strike Through: In contrast, strike through occurs when the resin migrates through the
interlining and surfaces on the top side of the fabric. This defect arises from excessive
heat and pressure settings, forcing the resin to penetrate through the entire fabric
thickness, appearing on the front side. Visible marks or stiffness on the fabric surface
can detract from the garment's aesthetic appeal and wearer comfort.

Advantages of Fabric Fusing Machines

Precision in Heat and Pressure Application: These machines can be preset for different
fabrics, reducing the risk of defects.

Automated Controls: Temperature control and safety features prevent overheating,

protecting the fabric.

Increased Production Capacity: Automating the fusing process enhances efficiency,

allowing for higher production volumes.

Reduced Labor Costs: Automation minimizes the need for manual labor, reallocating
resources to increase productivity.

Conclusion

The OSHIMA company is a leader in fusing machine technology and is known for its
high-tech, easy-to-use solutions that make making clothes more efficient and reliable.
Our machines are equipped with sophisticated features such as automatic temperature
control, comprehensive cooling systems, and rigorous safety measures, all aimed at
ensuring flawless fusing results. OSHIMA's unwavering commitment to exceptional
after-sales service further ensures minimal downtime, fostering continuous production
efficiency across the manufacturing spectrum.
Fabric fusing machines are essential equipment for the garment industry, offering
precise and efficient performance that greatly enhances the quality of the final product.
When manufacturers have a thorough understanding of the various fusing procedures
and strict control over the fusing circumstances, they may significantly limit the
possibility of mistakes, increasing production.

Types of fusing machines.

Fusing Machines are used in the garment industry to fuse a material

capable of being fused to a base fabric through the process of

pressure, heat, and time. The fused material should have acceptable

strength, the ability to stand continuous wash, or any fabric

treatment.

This extremely vital process that defines and maintains the quality

of the garment involves holding the fabric and interlinking the

conveyor belt while heating. This interlinking has adhesives that

melt at a certain pressure and temperature to bond with the

garment. This process provides the garment strength and support

and thus is a highly vital process.

There are a number of fusing presses deployed in the process that

makes the entire process of Fusing a quality procedure:

1. Continuous Fusing Press.

2. Flatbed Fusing Press
3. High-frequency Fusing
4. Hand Iron

Continuous Fusing Press

In this machine, the parts of the garment and the interlining are
placed one upon another properly for stiffening fabrics, among
other things. On the endless loop or loop-shaped feed sheet and fed
in a flat condition.
The feed sheet carries this part and the interlining to the fusing
chamber. In the fusing chamber, the required pressure and heat are
given.

To transmission of heat in the interlining, a direct or indirect

method is applied. After applying heat, the required pressure is
applied to the interlining with the help of a pair of roller irons.

The surface of the roller is generally covered by hard rubber. With

the help of spring or pneumatic power, the pressure is created in
rollers. And there is an arrangement of increasing or decreasing
heat. The preselected time is determined through the control of the
speed of the endless feed sheet.

Just after fusing, the fused parts are removed carefully from the
delivery sheet and in a flat condition. Because during removal of the
fused part in a heated condition., any folds created there may be
permanent.

One worker is persistently feeding, and another worker is

ceaselessly accepting the fused parts on the conveyance side.

The production of a continuous machine is high, and the quality of

the fusing is also good. In some machines, for double fusing, there
is an automatic feedback system. This is the most used machine in
the garments industry. These are often used to apply the best tape
that sticks to the fabric.

Advantages

1. The production of a continuous machine is high.

2. Quality of the fusing is good too.
3. For these reasons, it is mostly used in the garments industry.
 4. Very reasonable for stack fabric utilizing
5. There is no plausibility of fabric shrinkage

Disadvantages

1. It is suitable for woven/knitting fabrics

2. Whole role fabric and interlining are fusible because the
pressure is applied for a short time on the interlining and the
fabric. So, less chance of the plies of fabric being damaged.
3. The pressure is applied for a short time, so there is no chance
of fabric shrinking during the application of heat.

Uses/Application

1. High cost.
2. Because of its large area consumption, it’s difficult to
construct.
3. If the pressure roller is slanted or the surface of the roller is
uneven for any reason, or there is a difference of pressure in
the full diameter of the roller, the bond strength between the
components will be different.
1. Bacteria thrive in cold climates, and washing your laundry
machine with cold water will not do much to sanitise the
machine, and the garments would still be prone to both odour
and germs. So, even though lower temperature fabric washing
or machine cleaning can be environmentally friendly, it is not
hygienic. This is especially true for garment industrial laundry
machines or hospital laundry machines that deploy large-scale
fabric cleaning.
2. Therefore, besides using the detergent, make sure you use
slightly warm water and disinfectant while garment washing.
For machine cleaning, use a laundry cleaner and sanitiser
every once in a while, or every two months, depending upon
the cycles of machine usage, to make sure the machine is
thoroughly clean.
3. There is a myth that surrounds people that the more soap you
use, the cleaner and more sanitized your clothes will come out
of the washing machine. However, using more suds only builds
up as residue in the wash cycle, which is not entirely removed
and becomes a breeding ground for bacteria and moulds. This
also increases the odour of the garments and brings down the
hygienic level of your fabric.

Flatbed Fusing Press

In this machine, there are generally two beds; one bed is static
called ‘BUCK,’ and the other is moveable called ‘HEAD.’

The interlining and garment component is positioned first and

placed on the BUCK. The top of the BUCK is covered by some soft
beads made of fabrics, blankets, or silicone rubbers. The surface
buck and head are covered with fabrics having a coating of PTFE.
For this coating, the melted resins, dust, or spots can easily be
cleaned.

The heating system may be electrical or steam. Application of

temperature, pressure, and time could be pre-set in this machine;
hence fusing conditions are adequately maintained.

First, the part of the garment, which is for fusing, is placed flatly.
Then the resin surface of the interlining is placed carefully on this.
Due to switch operation, the HEAD moves downward and comes in
contact with BUCK, and pressure is applied on the component
(interlining). Temperature is applied through HEAD on the whole
surface, and after a specific time, the HEAD moves upward.

After applying pressure and heat up to a specific time, the HEAD is

separated from the BUCK. Then for cooling of the fused parts, an air
sucking fan in the buck is made operative. For sucking the air within
the buck, the fused parts are cooled very swiftly. Going up off the
HEAD and sucking of the air within the BUCK for a specific time.
These jobs are set in cyclic order in many machines.

Advantages

1. Temperature, pressure, and fusing time can be set again as

per will.
 2. Except for pile fabrics, mostly for all fabrics, this machine can
be used.
3. Low cost.
4. The natural ironing of garments can also be done with this
machine.
5. Tends to reduce fabric shrinkage.
6. Easily cleanable.

Disadvantage

1. Not suitable for large-scale production.

2. To get good quality fusing, the temperature, pressure, and
fusing time has to be checked.
3. Sometimes, HEADS and BUCKS have to be changed.

High-Frequency Fusing

1. This type of machine is quite different from a continuous

fusing machine. Because in this machine, heat is created the
same as a microwave cooker.
2. Fabrics and interlining are arranged in stacks and placed
between two metal plates of the fusing machine. The upper
plate exerts pressure on the plies of the fabrics and the
interlining with the help of spring pressure.
3. The material between the plates moves at high speed. So high
friction heat is generated within the material. This heat is
generated uniformly at the same time on every corner of the
fabric and interlining.
4. For the generation of heat, water is a must. The difference
between water vapour, the difference in heat may also happen.
5. The required fusing time depends on the electrical power of
the machine and the height of the lay of the fabric. But in this
type of machine, it takes 1to 3 minutes for fusing

Advantages

1. Production rate is high

Disadvantages

1. Before fusing this type of machine lots of caution has to be

taken care of. E.G., the setting, nature of the fiber, the height
of the lay of the fabric, amount of water vapour in the fabrics.
2. Proper settings of this machine are the main problem. Because
of complicated settings, there may be over fusing or under
fusing
3. This type of machine is minimal
4. Bigger risk of defective products.

Hand Iron

The interlining, which are fused comparatively in low temperature

and pressure, are fused by using a hand iron. These are mostly used
for applying lightweight fusible interfacing for applique.

There are various troubles during fusing; none of the three

parameters of temperature, pressure, or fussing time can be
adequately controlled. The operator approximates the time in this
manner.

So, the strength of the bond in this method is weak. For better
results after sewing the garment with the fusing, again, the final
fusing is done

Just little parts can be fused with any level of progress, and
afterward, only by pressing the iron for a fixed time onto the
fusible, covering the region bit by bit, and utilizing steam to enable
the warmth to move.

During the washing of the garments, the bond between interlining

and garments may be separated.

Hand irons are manually operated devices used to press and bond interlining to fabric, typically
on a smaller scale or for specific tasks in garment production.

Advantages:

1. Low Cost:
 o Hand irons are much cheaper to purchase compared to fusing machines, making
them ideal for small businesses or startups.
2. Flexibility:
o More versatile for smaller or more delicate pieces of fabric, allowing the user to
focus on areas that need attention.
3. Compact and Portable:
o They take up little space and can be moved around easily, ideal for small
workshops or at-home production.
4. Lower Energy Use:
o Uses less energy compared to large machines, resulting in lower operating costs.

Disadvantages:

1. Inconsistent Results:
o Since it's operated manually, the pressure and heat may not be distributed evenly,
leading to poor bonding quality.
2. Time-Consuming:
o Much slower than fusing machines, especially for larger-scale production.
3. Labor Intensive:
o Requires constant attention and manual effort, which can be tiring and less
efficient in the long run.
4. Limited Control:
o Temperature and pressure control is minimal, which can lead to fabric damage if
not used properly.