The manufacturing of flags is a story of technology as well as politics and history. It is a tale in which the advances made in technology over the centuries are reflected in how the flags are manufactured and what materials were used during the process. Essentially, there are two types of flags – sewn and printed. This includes both machine produced and custom printed flags.
Hand-Sewing, the Sewing Machine and the American Flag
The earliest types of flags were hand sewn. This process produced flags at a slow rate. Flag makers joined upholsterers when flags were in high demand to produce American flags during the War of Independence.
By 1840, the invention of the sewing machine changed the market. Usage grew until in the 1870s, sewing machines became available commonly. This sped up the work in the factories. A flag manufacturer welcomed this form of technology, although hand sewing was still done on many custom flags. In fact, sewing and hand dying remained until technology came up with chemical dyes. Nevertheless, hand or machine stitching of certain aspects of the American well e.g. the stars, remained well into the 20th century.
Printed American Flags
Printed flags are divided into two types: stenciling and printing. The older method is stenciling. The popularity of printing has increased over the years, although the state of Maine lays claim to the first multi-color printed flags. These were mass-produced in 1822.
In general, flag printing was slow to take off. Early flags that were printed were usually decorative in nature. They were often the type of flags waved during parades, hence the name “hand-wavers.” These flags were small. Their size range is between 3″ to around 3′ in length.
Sometimes the mass-produced flags were cheaply put together. The stars, instead of being sewn on were printed. This was not unusual for flag manufacturing during the civil war. By the 20th century, printed-flags were the norm. Huge machines rumbled in factories, as these mechanical devices swallowed roll after roll of fabric. The machines printed the same pattern repeatedly. The fabric was removed and taken to be washed and dried before being cut into individual flags.
The end of the 20th century saw a further development. Technology once again made its stamp on the flag industry. Digital printing has emerged. Custom printed flags are now easier to design and make. The colors, the styles, the ability to create any design imaginable are available at a fairly inexpensive price. While you can still purchase a traditional hand sewn flag, or arrange for a machine printed flag, it is now possible to purchase custom printed flags using the latest techniques.
