Combination embroidery/screen printing apparatus and method

A combination embroidery/screen printing apparatus for forming a plurality of reproductions of a selected pattern on at least one textile substrate, comprising;

• (a) a plurality of inner hoops for spacing on a first side of said substrate;
• each said inner hoop having a rigid, continuous, substantially planar, non-circular configuration with inside dimensions greater than corresponding dimensions of each said reproduction of said pattern;
• (b) a plurality of outer hoops for spacing on a second side of said substrate;
• each said outer hoop having a rigid configuration substantially similar to that of each said inner hoop;
• each said outer hoop having inside dimensions such that each said outer hoop substantially co-planarly encircles a respective one of said inner hoops when in a clamping relation therewith;
• each said outer hoop having a first mounting bracket with a transverse slot and a second mounting bracket with a longitudinal slot;
• (c) a frame having a screen tautly and adhesively secured to a planar face thereof for screen printing a first portion of each said reproduction of said pattern on said substrate;
• said frame shaped and dimensioned such that said frame is snugly slidably removably insertable in each said inner hoop such that said inner hoop substantially encircles said frame and such that said screen is placed in face-to-face abutting relationship with said substrate clampingly confined by said inner hoop in clamping relation with a respective one of said outer hoops;
• (d) a programmable, automated embroidery machine having a plurality of stitchers for simultaneously stitching a second portion of each said reproduction of said pattern into said substrate;
• (e) a platen for mounting said plurality of said outer hoops in side-by-side relationship thereon;
• said platen mountable in, and controllable by, said embroidery machine;
• (f) a least one planar, alignment template;
• said alignment template shaped and dimensioned such that said alignment template is snugly slidably removably insertable in each said inner hoop such that said inner hoop substantially encircles said alignment template;
• said alignment template having centrally located x-y axes inscribed on a face thereof such that one of said axes, as aligned, defines the desired vertical orientation of said reproductions of said pattern and the intersection of said x-y axes, as aligned, defines the desired designated center of said reproductions of said pattern;
• said alignment template having at least one lifter to assist with removal of said alignment template from a respective one of said inner hoops;
• and
• (g) an alignment platform for spacing adjacently to said platen;
• said alignment platform having a pair of parallel spaced guide rods, a stylus rod extending transversely from said guide rods, and a first stylus and a second stylus extending substantially vertically downwardly from said stylus rod such that, as said first stylus is spaced directly above said intersection of said x-y axes of an aligned one of said alignment templates inserted in one of said outer hoops mounted on said platen, said second stylus locates an off-center point of the desired orientation of said y-axis relative to said intersection of said x-y axes;
• said stylus rod slidably displaceable along said guide rods such that said first stylus and said second stylus are similarly, sequentially displaceable relative to one of said alignment templates inserted in each of the other said inner hoops clamped in a respective one of said outer hoops mounted on said platen.

A method for forming a reproduction of a pattern on a textile substrate comprising the steps of:

• (a) selecting a textile substrate;
• (b) installing a substrate in non-circular clamping means;
• (c) selecting first portions of said reproduction of said pattern to be formed by screen printing and second portions of said reproduction of said pattern to be formed by stitching;
• (d) preparing first artwork corresponding to said first portions and second artwork corresponding to said second portions;
• (e) preparing at least one first film positive corresponding to said first artwork and at least one second film positive corresponding to said second artwork;
• (f) preparing a framed screen from each said first film positive;
• (g) sequentially inserting each said framed screen in said clamping means, respectively screen printing said first portions of said reproduction of said pattern on said substrate, and respectively removing each said framed screen from said clamping means;
• (h) mounting said clamping means on a platen, and aligning said clamping means relative to said platen with an alignment template inserted in said clamping means;
• (i) mounting said platen in an automated stitching machine and aligning said platen relative to said stitching machine with said alignment template inserted in said clamping means and then removing said alignment template;
• and
• (j) stitching said second portions of said reproduction of said pattern into said substrate.