Printing for Christmas

We recently completed a 24′ h x 40′ w digitally printed project for Brian Setzer for the current “Christmas Rocks! Extravaganza” tour.  We have worked with this client before and enjoy doing their projects, and in the past have provided everything from traditional textiles to digitally printed backdrops to stage set elements.  But our most favorite time of the year is Christmas - we love to decorate and celebrate - and we always get excited about participating in Christmas shows, so this was a fun print project to tackle.

The project took one week to complete.  We did not design the artwork ourselves - instead it was build by the client’s own graphic artist as a vector file in Adobe Illustrator ®.  This was a cartoon-style graphic - lots of color and bright imagery. 

This type of graphic particularly lends itself to being digitally printed - the blues and bright tones show so well under concert stage lighting.

For this backdrop, we chose a heavy knit for two reasons.  First, in our industry, being flame retardant to national standards (at a minimum) is very important, and this material met the client’s requirements in terms of flame retardancy.  Second, knit type materials are perfect when the client needs to store the pieces folded up - when re-hung, the knit fabric relaxes and the wrinkles tend to hang out fairly well.  As you can imagine, in a stage or concert backdrop, clients don’t want to see wrinkles!

We use exclusively 3M inks with our 120″ Vutek QS3200 printer and use Colorburst for our RIP software.  I think the combination of the inks, the printer, and the software really come together for beautiful colors in the end product. 

For this project, print time took four hours, not including sewing / finishing time.  The piece was finished with webbing, grommets & ties across the top (we use a Jopevi electric grommet machine), which is a traditional backdrop finish.  The sides are durably hemmed (we prefer Consew brand commercial sewing machines) and the bottom is completed with a hidden weight pocket to help the drop hang nicely.

Offering digitally printed textiles in addition to our regular services is a benefit to our clients and allows us to keep the complete show in-house in terms of production.   I tend to post a lot about concert projects we work on - primarily because those are the projects that we can usually get photos of or find videos on YouTube.  However, as a full service sewing shop, we do produce all sorts of textile products for the theatre and stage, including traditional stage draperies, and more and more we are beginning to get request for digitally printed backdrops from schools, churches, and other non-tour customers - they really add a beautiful element to a show, and if the artwork is nice (such as a beautiful snow scene), the drop can be used at the annual holiday show for years to come.

If you enjoyed this post, make sure you subscribe to our RSS feed!

Swags and Digitals for the Eagles

Recently, both Sew What? and Rent What? had the opportunity to contribute custom stage drapery to The Eagles West Coast Tour, which opened on Monday in Portland, OR.

Production designer Butch Allen send us some rehearsals photos of our drapes on set - and I think they are just amazing!    Take a look at these Silver Swags from Rent What? :

Design: Butch Allen Designs; Photo Credit: Butch Allen

Also included in the rental package provided by Rent What? was a 24′ h x 50′ w backdrop, digitally printed by Sew What? to give the appearance of parchment (see the background in the photo above), as well as black masking pieces.

The tour also purchased a 24′ h x 24′ w custom digitally printed backdrop from Sew What?  Printed on clear vinyl, the clock image is dramatic while still allowing a view of the parchment backdrop behind it (as above).  Clever lighting in another scene makes the clock appear blue:

Design: Butch Allen Designs; Photo Credit: Butch Allen

More clever lighting, and somehow the drapery looks completely different:

Design: Butch Allen Designs; Photo Credit: Butch Allen

I can’t decide which of these three photos is my favorite; all three are just so beautiful.  Butch has created a wonderful set design, and I am so proud that Sew What? and Rent What? were brought on board to bring Butch’s vision to life. 

The show is in Seattle tonight, and then goes to Sacramento, San Francisco, Santa Barbara, and Los Angeles, before finishing up in San Diego on December 21st.  So, if you happen to get to one of the shows - check out the drapery and let me know what you think!

If you enjoyed this post, make sure you subscribe to our RSS feed!

Focus On: Double Kabuki Drapes

A couple of weeks, in my post on Single Kabuki Drapes, I promised that I would do another post on Double Kabukis.  Well, here you go!

A Single Kabuki allows a single release - the drape is hanging, the solenoids are released, and the kabuki drops to the ground.  With a Double Kabuki, through the use of either two sets of solenoids or one set in which each solenoid has two pins, a double release occurs. 

Initially, the kabuki is not seen by the audience.  It is hanging high up near the truss, enclosed in what is called a diaper.  For the first release, the first set of solenoids (or one set of pins) is released, and the bottom of the Kabuki drops toward the stage, allowing the audience to see the Kabuki.   On the second release, the second set of solenoids (or pins) releases the top of the kabuki (and in some cases the diaper) , which then drops to the ground.

A Double Kabuki is made in a very similar way to a Single Kabuki, with velcro on the top front and back, but doesn’t have velcro on the bottom.  The major difference is that a Double Kabuki also includes a diaper. A diaper is a soft good that is sewn at the same width as the Kabuki, but is only around 24″ high (this can vary depending on the fabric used on the Kabuki as well as the height of the Kabuki).   The top of the diaper is attached to the top back of the Kabuki, between the fabric and the Velcro.  The bottom of the diaper has velcro on the front and back.

To set up the Double Release of the Kabuki, the Kabuki is laid flat, front side up.  It is then rolled from the bottom to the top, until it is encased in the diaper like a sling.  Velcro D-rings are then attached to the top of the Kabuki/Diaper and to the bottom of the diaper.  The Velcro D-Rings on the top of the Kabuki are hung on one set of solenoid pins and the Velcro D-rings on the bottom of the diaper are hung on the second set of solenoid pins, leaving the Kabuki hanging unseen in a hammock high above the stage.

For the first release, the pins holding the D-Rings attached to the bottom of the diaper retract.  This causes the bottom of the diaper to drop behind and the Kabuki to unroll toward the stage.  For the second release, the pins holding the D-rings attached to the top of the Kabuki/diaper retract, and the Kabuki drops to the stage floor.

When might a Double Kabuki be used rather than a Single Kabuki?  Well, let’s say that a band has a dramatic printed backdrop, but they don’t want it to hang for the entire show.  Instead, they want it to be used only for part of the show (maybe even for just one song).  The band can start the show without the backdrop. 

When the desired time comes, the first release occurs and the printed backdrop suddenly appears as if from nowhere.  When the song or show section ends, the Kabuki then drops to the floor.

Another example of stage magic.  Pretty cool, don’t you think?

There’s one more related item, called the Poor Man’s Kabuki, but I’ll tell you about that in a future post.

If you enjoyed this post, make sure you subscribe to our RSS feed!

Mixed Media Backdrop? What’s that?

I seem to recall way back in grade school, doing “mixed media” art projects.  The fact is, I can’t really say that any of these “art” projects of mine were very artistic.  The best you could say about them was that they were “crafty” - bits of macaroni glued on a paper plate, bits of ribbon and sequins - something only a mother could love!

Here at Sew What? we have been exploring a new meaning for the term “Mixed Media,” and in my mind it really is a form of art.  In a stage backdrop context, “mixed media” refers to combining a number of different textural elements to make one dramatic piece of stage scenery.

Not sure what I mean?  Rather than trying to explain it, I’ll let some of our recent projects do the talking:

Mixed Media - Lady Gaga Style

• Digitally printed backdrop, with cut elements appliqued to scenery netting
• Attach to that a front projection screen for low res moving imagery
• Embed some LED lights on a basic battery pack, along with some smoke lines, for the gift that keeps on giving
• One backdrop and about 100 looks!  That’s Mixed Media Lady Gaga Style!

Mixed Media - Motley Crue Style

• Translucent poly substrate, digitally printed with bold graphics
• Take out various elements  and fill with mesh
• Add a backside applique in areas to reduce transparency strategically
• Rock it Crue-Style with front lighting looks and back lighting blow through, and then whip it away kabuki-style when you’re done!

Mixed Media - Soulja Boy Style

• All-American Red, White, and Blue backdrop on a traditional cloth substrate
• Step it up a notch with glossy lenses - digitally rear-printed clear vinyl elements appliqued into the design strategically to give the appearance of reflective sunglass lenses
• The result?  A dramatic backdrop that looks back at the audience! 

These are just a few examples of the huge diversity of looks that are achievable with a mixed media backdrop.  In the past, a scenic backdrop was simply fabric and a printed or painted image.  Now, with mixed media, a backdrop can be so much more. 

Mixed media is a concept that was introduced to us here at Sew What? a few years ago, and since then we have run with it and are continually “pushing the envelope” to find better and better ways to achieve the client’s vision in better and more innovative ways.  It’s not just about the fabric anymore!

If you enjoyed this post, make sure you subscribe to our RSS feed!

Can a Hand-Painted Backdrop be Certified FR?

While the majority of the scenic backdrops that we make are digitally printed, we do offer custom hand-painted backdrops as well.  In other situations, the client purchases a “plain” backdrop (typically in natural or white muslin) and then hand-paints it themselves.

Recently, a client asked us for a New York City Certification of Flame Retardancy.  We were providing the fabric and sewing the backdrop, but they were planning to paint it themselves.  In discussing the situation with the client, we realized that there are probably others out there wondering whether their painted backdrop can be certified as flame retardant.  So, here is a brief explanation.

Yes, if the fabric itself is flame retardant, the fabric can be certified as FR in NYC.  However, NYC regulations require a final FR certificate for the “completed composition,” of which the muslin is only one component.  Therefore, the certificate for the fabric alone will not suffice for a painted backdrop.

However, it is possible to get certification of a hand-painted backdrop, provided certain steps are taken:

1. Both the underlying fabric and the paint are flame retardant.  This would be accomplished by utilizing FR fabric (such as FR Muslin) and by adding an FR chemical to the paint used.  However, even with this step, the painted backdrop may not pass flame retardancy testing.  Therefore, it is recommended that the user (or a certified applicator) also spray the back of the painted backdrop with a flame retardancy chemical.

2. Contract with an registered NYC tester to have the backdrop tested for flame retardancy.

3. Prepare a sample of the painted backdrop (usually done by painting / FR treating a smaller sample piece at the same time as the main backdrop).  All treatment of the sample should be the same as that of the full-sized backdrop (i.e. the same original fabric should be used, as well as the same paints and FR chemical additive, and the back of the sample should be sprayed with FR treatment just like the full backdrop).

4. Write a statement verifying how you treated the backdrop (such as what FR chemical(s) was used and whether you added the chemical(s) to the paints and/or sprayed it to the back of the finished piece), and send the sample and statement to the NYC registered tester

5. The NYC registered tester will perform a “match test” to see if the sample meets NYC standards in regards to flame retardancy.  If so, the tester will provide you with a flame certificate, which you would show to the FDNY Fire Marshal onsite when the backdrop is in use in New York City. 

This is the process for New York City, but I am sure that a similar method would be conducted for other locations throughout the US.  If in doubt, check with the local or state fire marshal in your area.

If you enjoyed this post, make sure you subscribe to our RSS feed!

Textile mills moving to Mexico? Here’s an alternative

As you can imagine, the primary raw material that we use in our business is fabric.  We buy velours to make custom stage curtains.  We buy sharkstooth scrim to make theatrical scrims.  We buy printable fabric to make custom band backdrops.  All of these fabrics originate at the textile mill.

In general, those mills are located in the US or, in the case of certain specialty fabrics, in Europe (primarily the UK and Germany).  However, I have been hearing more and more about US textile mills opening new manufacturing locations in Mexico (especially since the adoption of NAFTA), with the primary workforce of these locations made up of local workers (though supervised by U.S. managers).  What does this mean for the future of the textile industry in the US?  I found an interesting article offering an alternative - Texas.

I have never been one of those people who is adamant on buying American goods, but I do worry about the future of the US textile industry and how it will affect companies like Sew What?

If you enjoyed this post, make sure you subscribe to our RSS feed!

Stage Curtains in Action

Since I started this blog, one of my goals has been to educate those readers who are new to the world of stage curtains and rigging.  Based on that, I have written various blog posts and included photos and links.  Today I thought I’d point you to some short videos that will show you stage curtains in action.  I hope you will find the videos both educational and entertaining.

Sew What? Inc. has posted several videos on You Tube.  This video shows an Austrian Drape being raised and lowered.  Make sure you turn the sound on your computer when playing the video - I think you’ll like the soundtrack!

We have also included an LED Star Drop that we made for the rental inventory of our sister company, Rent What?  I love the way the lights twinkle and flash - it is really a dramatic sight in a dark theatre or concert venue (again, try it with sound).

Our website has a large number of videos on it as well, showing a variety of custom stage curtains, custom band backdrops, and much more being used by artists as diverse as Lady Gaga, Rod Stewart, and James Taylor (and many more).  Check them out - I think you’ll enjoy them.

If you enjoyed this post, make sure you subscribe to our RSS feed!

Sew What? Travels the World

We’ve gotten some fun photos back from clients from time to time, usually of our drapes used in theatres or concert arenas or special event venues.  I always love to see our custom stage curtains, theatre scrims, and band backdrops in use.  But the photos below are different and gave me a chuckle, so I thought my readers might enjoy seeing them as well…

These Sew What bags are usually used for holding drapery - but here on a luggage carousel in Germany, it is apparent that someone ran short on space in their suitcase and decided to try out a Sew What? bag as checked luggage.

Each year we print a new Sew What? tee-shirt.  This is last year’s shirt hanging on a washing line in Italy.

If you enjoyed this post, make sure you subscribe to our RSS feed!

The Economic Downturn and the Textile Industry

It seems that the state of the economy is top of mind for just about everyone these days.  We hear a lot about how the economy has affected the auto industry, the housing industry, etc.  But the reality is that it is impacting just about every industry in the U.S., including the textile industry.

U.S. textile mills have been struggling against the influx of goods from textile mills in other countries, particularly India, Pakistan and China, for quite awhile now.   According to EconomyWatch, in 2007 production in U.S. textile mills fell by more than 12 percent.  ABC News reported that, from October 2007 through October 2008, about 100 textile mills in the U.S. closed, leading to the layoff of over 63,000 U.S. textile workers.  Now, with the downturn in the economy over the last six or eight months, things may be getting worse.

While the emphasis in these articles is on apparel textiles, the import of foreign textiles as well as the struggling U.S. economy has hit the U.S. textile industry as a whole, including those mills that specialized in theatrical fabrics.  We have certainly seen a trickle-down effect, but the most significant impact that I have seen over the last six to twelve months is on availability:

• Longer lead times.  In the past, it might have taken two weeks for milling, while now it may take four or six weeks.  I cannot say definitively the reason for the longer lead time, but I would guess that it is due to a smaller workforce (layoffs).
• Less In Stock.  Many of the large fabric suppliers are stocking fewer fabrics than they were a few years ago.  They just don’t want to tie up as much money in inventory, so they are waiting for firm orders before sourcing the fabric from the mill.  For suppliers with multiple stocking locations, they may stock some fabrics in one location only, rather than in several locations across the country. 

 So what does this all mean for the end-user – the school or church wanting new custom stage curtains or the rock band wanting a new custom backdrop?  In many cases, it may mean making a choice between waiting longer to get their drapery or choosing a different fabric that is readily available.  It may mean paying a higher price for a drapery due to the cost to bring the fabric in from a location out of state.  The best thing I can recommend is, be flexible and plan ahead!

If you enjoyed this post, make sure you subscribe to our RSS feed!

Is there such a thing as a “Green” ink for digital printing?

As I continue to explore the question of eco-friendly textiles, I have been thinking about digital printing. As more and more artists become interested in protecting the environment, we have begun to have more requests for “green” custom band backdrops.  We already have some eco-friendly options available for the fabric substrate, but what about the inks used in digital printing?  UV Curable, Water-based, EcoSolvent, Mild/Light Solvent, Full Solvent – which is best, ecologically speaking?

I would assume (based on the name) that a great choice for digital printing would be to use eco solvent inks.  The reality, however, is that these inks aren’t nearly as ecologically friendly as the name implies.  In researching eco solvent inks, I learned that they contain HAPs (Hazardous Air Pollutants) and VOCs (Volatile Organic Components).  Maybe eco solvent inks are better in comparison to other types of solvent inks, but that doesn’t mean they are good for us.

I’m interested in a new type of ink being touted by EFI – Bio-Solvents.  According to a white paper by EFI, bio-solvent Inks “contain no harmful VOCs and have the best health and environmental profiles available”.  EFI does make a bio-solvent ink (BioVu), so they aren’t exactly an unbiased source.  However, their literature does display the Environmental Protection Agency’s DfE logo, so I am feeling more confident (though I will continue to research this new category of inks before making a decision).

If this is all true, then bio-solvents may be the wave of the future.  Right now, EFI’s BioVu inks are only available for use with one printer type – EFI’s VUTEk 3360 product line – but they say that they have plans to roll it out to other product lines in the future.  I’ll keep my eyes out for it and let you know.

If you enjoyed this post, make sure you subscribe to our RSS feed!