Applique Printing Process And Machine

Abstract

A method and apparatus for creating a design that is melded onto an underlying layer of material that is then cut out and applied onto a final surface to produce an appliqué. The design is first created using a printer to print a design onto a top layer of “puff” or other suitable cloth material. The printed design area is cut out of the top layer material and then the bottom layer, to create a two layer appliqué that resembles a traditional stitched appliqué.

What is claimed is: 
     
         1 . An automated process for creating a printed design resembling a needlework appliqué, comprising the steps of:
 (a) printing a design onto a first layer of material; 
 (b) attaching the first layer of material to a second layer of material; 
 (c) cutting a portion of the first layer of material with a laser cutter to reveal at least a part of the second layer of material; 
 (d) cutting the second layer of material to separate the design and a portion of the second layer of material into an appliqué; and 
 (e) removing waste portions of the first material and second material using an extraction method. 
 
     
     
         2 . The method of  claim 1 , wherein the extraction method is selected from the group consisting of blowing a compressed gas, mechanical picking, and gravity. 
     
     
         3 . The method of  claim 1 , wherein a dotted line is printed onto the first layer of material to resemble stitching. 
     
     
         4 . The method of  claim 1 , wherein a portion of the first layer of material is cut to resemble stitching. 
     
     
         5 . The method of  claim 1  wherein the first layer of material is heat activated puff material. 
     
     
         6 . The method of  claim 5 , wherein the extraction method is selected from the group consisting of blowing a compressed gas, mechanical picking, and gravity. 
     
     
         7 . The method of  claim 5 , wherein a dotted line is printed onto the first layer of material to resemble stitching. 
     
     
         8 . The method of  claim 5 , wherein a portion of the first layer of material is cut to resemble stitching. 
     
     
         9 . The method of  claim 5 , further comprising the steps of:
 (a) attaching the appliqué to a third material; and   (b) heating the appliqué to cause the puff material to expand.   
     
     
         10 . An on-demand automated process for creating a printed design resembling a needlework appliqué, comprising the steps of:
 (a) receiving a design designated by a customer; 
 (b) formatting the design for computerized printing; 
 (c) directing with a computer the printing of the design onto a first layer of material; 
 (d) attaching the first layer of material to a second layer of material; 
 (e) cutting a portion of the first layer of material with a laser cutter to reveal at least a part of the second layer of material; 
 (f) the second layer of material into an appliqué; and 
 (g) removing waste portions of the first material and second material using an extraction method. 
 
     
     
         11 . The method of  claim 10 , wherein the extraction method is selected from the group consisting of blowing a compressed gas, mechanical picking, and gravity. 
     
     
         12 . The method of  claim 10 , wherein a dotted line is printed onto the first layer of material to resemble stitching. 
     
     
         13 . The method of  claim 10 , wherein a portion of the first layer of material is cut to resemble stitching. 
     
     
         14 . The method of  claim 10  wherein the first layer of material is heat activated puff material. 
     
     
         15 . The method of  claim 14 , wherein the extraction method is selected from the group consisting of blowing a compressed gas, mechanical picking, and gravity. 
     
     
         16 . The method of  claim 14 , wherein a dotted line is printed onto the first layer of material to resemble stitching. 
     
     
         17 . The method of  claim 14 , wherein a portion of the first layer of material is cut to resemble stitching. 
     
     
         18 . The method of  claim 14 , further comprising the steps of:
 (a) attaching the appliqué to a third material; and   (b) heating the appliqué to cause the puff material to expand.   
     
     
         19 . The process of  claim 10 , wherein a plurality of customers each designate a design and the operation of the process to generate the designs of the plurality of customers is continuous. 
     
     
         20 . The process of  claim 18 , wherein a plurality of customers each designate a design and the operation of the process to generate the designs of the plurality of customers is continuous.