Fusing machines are usually of four types –
- Continuous Fusing Press
- Flatbed Fusing press
- High-Frequency Fusing
- 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 rollers.
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 removing 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 fabric.
- The production of a continuous machine is high.
- Quality of the fusing is good too.
- For these reasons, it is mostly used in garments industries.
- Very reasonable for stack fabric utilizing
- There is no plausibility of fabric shrinkage
- High cost.
- Because of its large area consumption, it’s difficult to construct.
- 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.
- It is suitable for woven/knitting fabrics
- Whole roll of 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 to be damaged.
- The pressure is applied for a short time, so there is no chance of fabric shrinking during the application of heat.
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 bead made of fabrics, blankets, or silicon 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 garments, 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 creates 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, 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 of the HEAD and sucking of the air within the BUCK for a specific time. These jobs are set in cyclic order in many machines.
- Temperature, pressure, and fusing time can be set again as per will.
- Except for pile fabrics, mostly for all fabrics, this machine can be used.
- Low cost.
- The natural ironing of garments can also be done with this machine.
- Tends to reduce fabric shrinkage.
- Easily cleanable.
- Not suitable for large scale production.
- To get good quality fusing, the temperature, pressure, and fusing time has to be checked.
- Sometimes HEADS and BUCKS have to be changed.
- 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.
- 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.
- Within 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.
- For the generation of heat, water is a must. The difference between water vapor, the difference in heat may also happen.
- 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
- Production rate is high
- Before the 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 vapor in the fabrics.
- Proper settings of this machine are the main problem. Because of complicated settings, there may be over fusing or under fusing
- This type of machine is minimal
- Bigger risk of defective products.
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.