The pattern design department in our factory creates the camouflage patterns, of which we display a small portion on our website, and new patterns are added to these patterns every day.

Special pattern and colour studies for different brands are also carried out in our design department, and as a result, each brand is provided with patterns and colours that reflect its own style.

The sublimation printing technique is used to print the patterns that we designed in our factory. To summarise, sublimation printing is a printing technique in which the dyestuffs used in printing evaporate at high temperatures, allowing the dyestuffs to penetrate the filaments of the polyester yarn in the jersey fabric.

Advantages of Sublimation Printing;

– It allows you to see the design’s colour vibrancy and pattern details to their full extent on the jersey.

– It is colourfast to a high degree. Textile printing, for example, uses drum printing. The binder and other dyestuffs are used in the printing technique known as names. Binders ensure that the dye adheres to the yarn’s surface, and the rate of dye penetration into the yarn is much lower than with sublimation printing. The dye is allowed to penetrate the yarn filament directly in the sublimation printing system. This guarantees that the colours will last a long time.

– Although the sublimation printing technique has a relatively high unit cost, it has a high production speed, allows for maximum colour and pattern intervention, has a low minimum manufacturing quality, and, most importantly, maintains colour vibrancy for much longer than peer-to-peer printing.

By cutting the neoprene blocks we supply from leading neoprene manufacturers with our horizontal cutting machine, which we added to our manufacturing park in 2020, we hoped to speed up the production process and improve its quality.

In the manufacture of Wetsuites, neoprene is the primary raw material. Neoprene is made up of blocks called “Billets” that come in various thicknesses depending on the intended use, content, and, of course, the manufacturer’s preference. Contrary to popular belief, neoprene 3mm, 5mm, and other thicknesses are not interchangeable. There are no standard thicknesses available (with exceptions). When the chemical production phase is finished, neoprene is usually cut into blocks of 30mm to 45mm in height. These neoprene blocks are then sliced into various thicknesses based on the requirements (usage area of the product to be manufactured). Neoprene is a flexible material that is also resistant to impact and abrasion. As a result, slicing (horizontal cutting) of neoprene blocks in various thicknesses is done with machines designed and manufactured specifically for cutting neoprene material.

What is Lamination?

In short, it is the process of covering neoprene material with jersey fabric.

Lamination in Wetsuit Production;

A lamination system known as “Hot Melt,” is used to coat neoprene material with jersey. When film lamination and other lamination techniques are not used in the production of Wetsuites, the elasticity of the neoprene is reduced, causing Wetsuites used in relatively challenging natural conditions to be damaged in a short period of time. For the comfort and durability of Wetsuites, the lamination phase of production is crucial. The correct formulated adhesive should be applied in the correct machine under controlled conditions.

Lamination Department and Capacity;

We perform the lamination process as Free-Sub using an adhesive designed specifically for neoprene and our machine, which we added to our manufacturing park at the end of 2016.

Our lamination machine has a production capacity of 1200 metres per hour on average. We can laminate 550 pieces of a 2.20-metre-long standard neoprene sheet in 1 hour using a simple calculation.

How does the lamination process take place?

Different components specially manufactured for neoprene are combined with a standard formula just before the lamination process, and the adhesive to be used in production is obtained in the form of “Hot Melt” lamination. After that, the task of the lamination machine designed specifically for neoprene material lamination takes over. At each point, the lamination machine applies an equal density and appropriate amount of adhesive to the neoprene sheet, and then combines the jersey and neoprene with the required standard pressure. The neoprene coated with jersey is then passed around a hot drum with a three-meter diameter and high temperature to dry the adhesive.

Wetsuites are primarily designed to provide water and heat insulation, as well as comfort and ergonomics. The manufacturing technique and machines used to provide the above features are not typical of textile manufacturing.

During the initial stage, all parts are usually glued together with special adhesives. Because waterproofing is the primary goal, it is critical that this process be carried out with care and using the proper adhesive. Following that, these joints are sewn together using sewing machines designed specifically for the industry, preferably with high-durability polyester threads. Blind stitch is a common sewing technique used in the construction of Wetsuites. There is no double-sided pinhole with this sewing technique because the skewers do not pass to the other side of the neoprene fabric during sewing, so an assembly that increases waterproofing is provided.

Our apparel track’s average monthly production (for hunting suits) is 5000 pieces as a Free-Sub. Simultaneously, production of other neoprene products and accessories (diving socks, gloves, and so on) continues unabated.