Flock fabrics are made by adhering short, coloured nylon, rayon or polyester strands directly on to a flexible substrate such as
paper, to provide a material that looks something like wallpaper when finished.
Making The Flock Side Elements
The fine flock strands, which are usually between 0.25 mm - 0.5 mm in height, are electrically charged to keep them upright. This provides
a tough, durable and visually appealing material with that classic ‘suede’
effect for which flock fabric is well known.
Applying flock fabric linings is a craft skill which takes
several years to perfect and is always undertaken by hand. The skill is similar
to that of a tailor cutting fabrics for suits etc, although on a much smaller
scale.
Adding The 'Flock Hinge' & Side Elements
Flock fabric linings are normally applied flat and glued to
the inside surfaces of wooden boxes, using a glue gun. Glue guns work by
inserting a clear glue rod into an appliance that looks a bit like a
small electric drill. The glue is melted by an electrical heating element and
is then discharged at the nozzle, using a trigger.
Individual pieces of flock fabric are first carefully cut
with a sharp knife or scissors and stretched over the joint between the lids and the bases of
the wood boxes. The flock fabric pieces are then stapled in position on both sides of the joint, providing what is
essentially a ‘flock hinge’.
Adding The Final Flock Lined Base Element
Individual elements for the bases, lids and sides of the wooden boxes are then
made up and comprise flock fabric stretched over and around stiff cardboard pieces
that are carefully cut to size and glued in position, to provide a smooth, even finish.
The final inspection ensures the flock fabric linings are finished to the required high standards and the wood boxes function correctly.
This may involve a degree of ‘fabric tucking’ which is usually undertaken with a sharp
scalpel knife.
The Finished Flock Lined Polmac Box
