Digital printed applique emblem

A method for providing digitally printed appliqué indicia, comprising the steps of:

• designing an emblem graphic design using computer drawing software, said emblem graphic including a multi-color print element and a simulated embroidery element around a periphery of said multi-color print element depicting embroidery-stitched thread entering a series of simulated holes, and generating a separate print output file from said emblem graphic design in raster format for printing said multi-color print element and simulated embroidery element by a digital printing station, and a separate cut/etch output file from said emblem design in raster format;
• converting said raster-format cut/etch output file to a vector-format cut/etch output file for cutting and etching said simulated embroidery element by a digital laser;
• digitally-printing said emblem graphic design on one side of the fabric substrate at said digital printing station in accordance with said raster-format print output file;
• digitally etching the one side of said fabric substrate in accordance with said converted vector-format cut/etch output file where the embroidery-stitched thread of said simulated embroidery element enters said simulated holes to add a recessed three-dimensional texture to said simulated embroidery element;
• applying a thermally activated or pressure sensitive adhesive coating to another side of the fabric substrate;
• and
• cutting the bonded fabric substrate and carrier in accordance with said converted vector-format cut/etch output file.

A method for providing digitally printed appliqué indicia, comprising:

• a design phase in which a distinct art file is digitally created in raster format using raster imaging software for newly generated art or is derived from a pre-established design, said distinct art file comprising a multi-color print element and a simulated embroidery element around a periphery of said multi-color print element depicting embroidery-stitched thread entering a series of simulated holes, and engraving and cutting elements are created in raster format and incorporated in the image file or in one or more other files;
• a separation phase in which the engraving and/or cutting elements are converted from said raster format to a separate vector cut file(s) to optimize cutting speed;
• and
• a printing phase in which the raster format multi-color print element is input into a digital printer for translation of the pixel color values to obtain the optimal color match for driving the digital printer based on the ink dye set used by the printer, said simulated embroidery element is input to said digital printer, and in which said printer precisely applies ink droplets to a front side of a fabric substrate to depict said multi-color print element and simulated embroidery element;
• a coating/laminating phase in which the printed substrate is coated with a thermoplastic or pressure sensitive adhesive on a backside of said fabric substrate for later application to a garment;
• and
• an etching/cutting phase by which said converted vector cut file(s) containing said etching and cutting elements are input to a digital laser for laser-etching of the front-side of the emblem to texturize and accentuate a textured appearance of embroidery stitching, and digitally etching the fabric substrate at said digital laser in accordance with said converted vector cut file(s) where the embroidery-stitched thread of said simulated embroidery element enters said simulated holes to add a recessed three-dimensional texture to said simulated embroidery element;
• and
• die-cutting or laser-cutting of the emblem from the substrate.