Behind the Scenes: Printing & Producing Your Backdrops

Creating high-quality backdrops is a process that demands precision, attention to detail, and the right materials. At our print lab, we specialize in producing backdrops using Fleece and Ultra Cloth, both of which are renowned for their unique qualities and versatility. Here’s a glimpse into the process behind the scenes, from preparing the materials to the final product.

Step 1: Selecting the Right Material

While the sublimation process is consistent, the choice of material plays a significant role in the final outcome of a backdrop. Both Fleece and Ultra Cloth have their advantages, making them suitable for different applications:

Fleece: Known for its rugged durability, fleece is the top choice for backdrops that excel in any environment. Fleece backdrops hang beautifully and are highly valued for their natural ability to shed wrinkles when hung, even without a pole pocket. Fleece backdrops are more opaque than Ultra-Cloth, making them ideal for environments with harsh backlighting. Their natural ability to absorb light allows them to perform exceptionally well in challenging, less controlled lighting conditions.

Ultra Cloth: Our most wrinkle-resistant option, Ultra Cloth backdrops are celebrated for their vibrant color "pop," delivering stunning results in controlled indoor settings where lighting can be carefully managed. While they excel in these environments, bright outdoor light may cause background highlights to show through, making Ultra Cloth best suited for indoor use. The material is designed to print the entire image without requiring a bleed, ensuring that the full image is beautifully displayed on the cloth. Ultra Cloth backdrops also include a convenient pole pocket and, like Fleece, are both machine washable and dryable.

Step 2: The Printing Process

With the material selected, the next step is the printing process. We utilize a sublimation printing technique, which is essential for creating backdrops with vivid, long-lasting images.

Sublimation Paper: The sublimation process begins with a special type of paper known as sublimation paper. This paper is coated to hold sublimation inks until they are transferred onto the backdrop material. The key feature of sublimation ink is its ability to turn into gas when heated, allowing it to bond with the fibers of the material, creating a permanent and vibrant image.

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Printing the Design: Once the design is ready, it is printed onto the sublimation paper in a mirror image. This ensures that the design appears correctly when transferred onto the backdrop. Careful attention is paid to the alignment and positioning of the design, especially with larger backdrops where precision is crucial.

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Heat Transfer: The next step involves transferring the printed design onto the fleece or Ultra Cloth using a heat press. The heat press is set to an appropriate temperature, typically between 380°F to 400°F (193°C to 204°C), depending on the material. When the press is applied, the sublimation ink turns into a gas and permeates the fibers of the material, creating a vibrant, durable, machine washable image that becomes an integral part of the backdrop.

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Step 3: Finalizing the Backdrop

After the sublimation process, the backdrop is carefully inspected and finished to ensure it meets our quality standards:

Cooling and Inspection: Once the heat transfer is complete, the backdrop is removed from the heat press and allowed to cool. It is then inspected to ensure that the colors are vibrant, and the image is free from any imperfections

Trimming and Sewing: The backdrop is trimmed to the desired size. For Ultra Cloth backdrops, a pocket is sewn into the material for easy hanging with a pole. Fleece backdrops are made from pre-sewn blanks without additional finishing needed. Their rugged nature ensures durability without the need for extra treatment.

Final Quality Check: Before the backdrop is considered complete, it undergoes a final quality check. This includes verifying that the material has maintained its integrity throughout the process and that the design is perfectly rendered.

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Producing backdrops using Fleece and Ultra Cloth is a careful and precise process that brings together the best of both materials. Whether you need a backdrop that can withstand outdoor conditions or one that delivers a stunning visual impact in indoor settings, our print lab ensures that each backdrop is crafted to meet the highest standards. By understanding the process behind the scenes, you can better appreciate the craftsmanship and dedication that goes into creating each of our custom backdrops.

All BackgroundTown backdrops are meticulously produced under the stringent standards set by American Color Imaging (ACI) in Cedar Falls, IA. Each backdrop undergoes rigorous quality checks and is crafted with precision, ensuring it meets the high expectations our customers have come to trust. Proudly made in the USA, our backdrops reflect the dedication and craftsmanship that come from a company deeply rooted in American manufacturing traditions.