Liquid Silicone 3D Embossing Process

The embossing material is applied to the embossing area of the fabric using either the "doctor blade coating" or "screen printing" method:

1. Doctor Blade Coating

Secure the fabric to a workbench (the tabletop must be flat and can be covered with a non-slip mat).

Pour the embossing material along the edge of the fabric.

Use a stainless steel doctor blade (held at a 30–45° angle with uniform pressure) to scrape the material in a single direction.

Control the coating thickness according to the pattern requirements: typically 0.3–1 mm for standard designs, and 1–2 mm for 3D patterns to enhance dimensionality.

Ensure the coating is free of gaps (missing areas) and air bubbles.

2. Screen Printing

For complex patterns (e.g., fine textures or intricate designs):

Prepare a screen stencil matching the target pattern. Select the mesh count (80–120 mesh) based on the material's viscosity-lower mesh counts are suitable for higher-viscosity materials.

Lay the fabric flat on the printing table. Align the screen stencil with the positioning lines marked on the fabric to ensure pattern accuracy.

Pour the embossing material onto the screen stencil.

Use a squeegee (with a hardness of 70–80 Shore A) to press vertically and scrape the material across the stencil. Ensure the material fully penetrates the gaps between the fabric fibers for strong adhesion.

3. Positioning and Pressing

Transfer the fabric with the applied embossing material to the embossing machine's workbench.

Align the fabric with the embossing mold according to the design position (positioning marks such as alignment lines or registration holes can be attached to the workbench to prevent pattern misalignment).

Start the embossing machine and apply pressure:

0.3–0.6 MPa for silicone embossing;

0.2–0.4 MPa for PU adhesive embossing;

Reduce pressure to 0.1–0.2 MPa for knitted fabrics to avoid fabric deformation.

Maintain the set temperature during pressing. Adjust the pressing time based on the material's curing speed:

10–20 seconds for silicone embossing;

8–15 seconds for PU adhesive embossing;

Extend the time for thicker coatings (e.g., 25–30 seconds for 2 mm-thick silicone).

Key Principle

During the heat-pressing process:

The embossing material cures (hardens) under heat.

The 3D texture of the mold is "replicated" onto the surface of the material, forming the desired raised pattern.

Active components in the material (e.g., silane coupling agents in silicone) undergo a chemical reaction with the fabric fibers, creating a strong and durable bond.