How is a Polyknit Flag Made?

How are our flags created? At The Custom Windsock Company, we are passionate about our products. We strive to source the best fabric and we take great pride in our process.  All of our flags are made with care and quality checked before leaving our premises

4 Steps to Making a High Quality Flag

1. Sourcing

Our flags are made of a knitted polyester fabric that is specially created for the flag industry. It is coated with a UV resistant coating to prevent as much sun damage and fading as possible. 

2. Printing

Our flags are digitally printed on the fabric using a method that results in a 100% bleed through on the reverse side. This means that, unlike competitor products, our flags look the same both forward and backwards in terms of the vibrancy and colour. No matter from where you see the flag, you see it with the same vibrancy and vivid colours. 

Digital Printing

Custom flags are digitally printed. When we receive an order for a custom flag, we work with the customer to understand their needs. Our graphics team finalizes artwork with them and once our customer approves of the proof we send them; we send their customized flag to the printers.

Using the same UV coated knitted polyester fabric, we use a process called acid dye printing, specific to the flag industry, to digitally print the image onto the polyester sheet. Acid dye printing uses a chemical to allow the dye from the digital print to penetrate through the fabric so it can be clearly seen on the reverse side.

3. Curing

Once a flag’s graphic is printed onto the Polyknit material, whether screen printed or digitally printed, the fabric undergoes a curing process within the machine. All of our Polyknit flags are heat cured after being printed to impregnate the ink within the fabric. Once the flags have been cured, the richness of the colours comes through.

4. Sewing and Finishing

The flag then moves from our curing department to our finishing department where employees sew the flags. Our flags are quadruple stitched at the fly end to ensure we minimize wear and tear from wind damage. We also use a special canvas white polyester header for the flag as opposed to just sewing in a cheaper polyester header so that the flag is reinforced at the header creating a sturdier product. We then sew in either grommets or create a header for rope and toggle as per the customer’s request.