How Logo Mats are Made
When you place your order for a logo mat, the first thing we do is to transfer your ideas into a design or you can supply your own design.
When the design is approved the artwork is converted into the standard colours and format to suit the printer we are using. Quite often we have to increase the thickness of fonts and lines etc. to make sure they can be seen on a mat. As a rule of thumb, any readable content should be more than 4-5 mm so it is not lost in the pile of the mat.
When the graphic file is approved, we schedule the mat for production.
The Zimmer printers are loaded with plain white carpet. All the different designs from our clients are pieced together to print the full width of the carpet (hence our standard widths). The carpet is printed using a state of the art “Chromo Jet Method” the ink is precisely pressure injected into the carpet to make sure that the ink penetrates right through to the backing. After printing the carpet passes through a steamer, which “Fixes” the ink. The carpet is then dried.
When dried the carpet is laid out on the cutting table. The automated cutter follows lines on the carpet to cut out the individual mats.
The next stage is the 100% nitrile rubber backing. A sheet of nitrile rubber is cut larger than the finished mat and the mat is placed on top of the rubber. If a gripper back is required a metal template is placed under the rubber. They are then placed into a heated press to bond them all together.
After cooling the rubber is trimmed to allow borders or if requested, no border. For our exclusive mats, an additional layer of rubber is added to the edges and heat welded together to form a solid rubber edge.
The mats are then packed and shipped to you.