Blog — tyvek

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Introducing MONYOU Series Japanese Prints

I’m pleased to introduce the MONYOU Series- a limited edition collection of prints inspired by traditional Japanese patterns.
Monyou Japanese Prints

View MONYOU Collection

This distinct style is characterized by repeating geometric patterns which reflect those found in nature. The tradition dates back over 500 years when bold patterns were needed on flags to distinguish different groups on the battlefield from a distance. From there, they began to be used as family crests and as motifs on crafts.


Modern Material with a Traditional Twist

Featuring clean lines and bold patterns, this collection is a blend of modern and traditional. For example, patterns like this would commonly be found on washi paper. The texture in this traditional paper is often visible, adding a unique character to the print. Our modern Tyvek material achieves the same effect due to the random swirls of fibers that are used to create it.



Design Process


You may not have been aware, but one of my close friends Damon has been the unofficial Creative Director for SlimFold for years. I’ve always bouncing ideas off of him and he even helped shoot our first two Kickstarter videos! I was thrilled that this year he was able to contribute in a more official capacity on several projects. When it came time to do a new print run, I offered him three slots on the press sheet as a “blank slate”. He came up with several ideas which pushed the limits of how we produce the wallets in order to achieve them.

We made no compromises to the design vision and spared no expense creating these wallets. We’ve traditionally done 1-colr print jobs and utilized screens to achieve different variations. This allowed us to use PMS spot colors and achieve colors that are deep, vibrant, and exact color matches. But these patterns required a 4-color print run. By working closely with the printer, we were able to achieve exact matches across all of the colors and still achieve the deep colors we were after.
MONYOU Flower Pattern

Next was the cutting. With the color break on the fold of the Aqua Star pattern, registration had to be perfect. I coordinated with the local die cutter before the print run to set things up so we’d have a shot at pulling it off.
MONYOU Star Pattern

View Star Pattern 

There was a very real possibility that none of these patterns turned out well once we printed them. Or that they would get destroyed in the process of cutting them. I’m happy to say that our production partners were able to deliver on all of them.

MONYOU Wave Pattern

Though Damon now lives on the East Coast and contributed his designs from afar, he was able to stop through California for a few days and we did a photo shoot together. From concept all the way to the final images, this project is Damon’s creative vision. I’m glad I could help bring it to life with this project.

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Designed and made in California

It’s been interesting to hear how the reaction to the fact that we make our products in California has changed since 2009. Initially, it wasn’t surprising because we were really small and just selling things at booths in local design street fairs. Folks weren’t expecting these things to be coming in on container ships.

Over the next few years, people got used to the fact that more and more of their products were made abroad. So folks seemed to find it refreshing to hear that we still made SlimFold wallets in USA.

Made in USA Minimalist thin Tyvek MICRO wallet
Recently, with the rise of Amazon, private labeling, and drop-shipping, more and more small companies have been importing their products. And the reaction from other business owners and some new customers to the fact that we don’t has been one of genuine surprise and confusion. The first thing they say is, "Why?”

So I thought I’d reflect on that a bit and explore just a few of the reasons that companies make things locally...

Marketing
For many companies the answer begins and ends with marketing. They want to be able to say they make their products in a particular place and try to make the economics work. For leather handbags to say they’re made in Italy, companies have gone so far as to make their products in China but not connect the handle to the bag. Then this “final assembly step” which technically defines its origin is done in Italy, along with sewing in the “Made in Italy” tag. 

Product Quality
While I am proud that my products are made in the USA, the fact that they’re made here has a bit more to do with the organic nature of how I partner with local shops to bring my products to life. 

Bob's Foam

I tend to solve design problems by applying advanced production techniques and I’m continually amazed by the local companies I discover who have the equipment I’m looking for and the expertise to get amazing results with it. In this way, the product design and quality is usually enhanced by this collaboration with the actual makers.

By integrating these local companies into the late stages of prototyping, and often using the same providers for both prototyping and production, the transition into manufacturing is seamless and quality remains high. 

Contributing to the Local Economy
For whatever reason, most of the companies I end up working with are Father-son teams… or in one case, a daughter who became the CEO. But I don’t see it as doing any favors for these companies. Instead, they’re almost extensions of my team who I depend on at least as much if not more than they depend on me.

Is it important to you?
One of the reasons I’ve begun to think about this more is based on customer feedback. There are some customers who would rather pay a lower price, so interpret the fact that we make our products in California as a needless extra expense for them. I can understand this and also wish more folks would be able to afford and enjoy what we make. 

As it stands now, making these products locally is integral to the design process and location of the labor can’t be substituted 1:1. So the existence of the products is an extension of the design process, which happens to take place in California. More like growing grapes for a wine in a particular place than the formula for coke which can be made anywhere.

That’s not to say it would be impossible to transplant our process and manufacturing somewhere else, but we’re currently focusing our efforts on developing new products instead.

So that’s my current thinking on why we make stuff here. Just like I don’t see myself as doing any favors for our local partners by making our products here, I hope you can also see the value in the products we create regardless of where they’re made.

I’d love to hear your thoughts on the topic in your comments below….
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New Black Tyvek Print Run: Challenges and Solutions

If printing on Tyvek were easy, I probably wouldn’t have a company. Not because of the competition of everyone doing it, but because I would have been able to make just a few wallets in the beginning. 

Since the material is essentially a sheet plastic, it’s really hard to even put ink down on it and get it to adhere at all. Special commercial presses are required so right away you’ve got to print many thousands of them even if you want just one.

To get the printing quality I wanted, I had to produce so many that it made sense to sell the extra ones... so SlimFold got it's start.

Process

The process of printing on Tyvek actually has a lot of variables. First, there’s the type of Tyvek to choose. It comes in a fabric style, which is what clean room “bunny suits” are made of, and also a paper style used for FedEx mailing envelopes. I use the paper-like one but even then, you can get a variety of thicknesses, coatings, and even textures.

Next is the ink. This is one of the keys since they have different properties. The ones that will stick to Tyvek at all can only be applied with a commercial press. In addition to adhering to the Tyvek material, it also needs to resist the abrasion of taking it in and out of the pocket.

Finally is the press itself. Some inks and processes can only be achieved with specialized equipment. Just like laser printers and ink jets, the ink and the printer needed to apply them are completely different.

The issue

One thing that’s very difficult to account for is how things will wear over time. This is especially true of things which whose wear patterns differ from customer to customer. Let me ask you a question: How long do jeans last? Well, although denim is very durable and stays functional for a very long time, it may not stay looking new for it’s entire serviceable lifetime. So you may need to buy new "work jeans" fairly frequently if you work in an office. But if you work in construction, it may not matter how they look but because of how hard you use them, you still may need to replace them more often.

Similarly, Tyvek wears in over time and looks less new. Most of the time, folks are amazed by how long their wallets last and we’ve got tons of repeat buyers who get fresh ones once their old one no longer looks new enough. But then we had several folks reach out who weren’t happy with how the printing wore. As you can imagine, this was extremely difficult to troubleshoot. How were each of the people using it? How many cards did they have? And if something wasn't right with the printing, how can we even tell which print run their wallet came from?

Solution

Luckily, it was the feedback from customers which ultimately helped us figure out what was going on. The first trend we noticed was that it only seemed to only affect black wallets. With all the variables involved, could the ink color also be one? Or was that just a function of the fact that it’s the one we sell the most number of?

My approach to creating products is to put in the hard work of designing it right in the beginning, partner with local vendors to fine tune production, and add a product to my line. When I’m getting close to running out of stock, I go back to those same vendors to produce more. When I talked to the printer, it turned out they had modified their press just before my most recent run. This should have theoretically improved things, but the new press modification also used a new ink. They said there are a variety of black inks available from different manufacturers, each with slightly different properties depending on their formulation. As discussed in this post, there isn’t really a way to “proof” things on Tyvek to make a test print. So how could I know which was the best to use?

To test them, we essentially had to do a mini print run using all of the different blacks on one sheet.

Tyvek Print Test

After the print run was done, I devised an abrasion test: a 320 grit fine sandpaper attached to a cylinder with a specific weight. I then dragged it parallel to the surface, allowing only the force from the weight of the cylinder to transfer to the surface. Okay, that’s a fancy way of saying I taped some sandpaper to a roll of duct tape, but it was a little scientific, ok?

Testing Abrasion of Tyvek Printing

It let me see what the wear was at 10, 20, then 40 rubs… and then compare that to another sample print. While this wouldn’t give us an absolute measure of abrasion resistance, it was good enough to show which printing method was best. I also compared it to sample press sheets from each of the previous 7 print runs we’ve done. Interestingly, this also confirmed the trend of previous print runs being better and the latest one not being quite as good.

Just to be sure, we then also sent all of the print samples to DuPont, the manufacturer of Tyvek, where they had a sophisticated abrasion testing machine. The lab results matched what I had found with my simple sandpaper test so we had a winner.

Conclusion

Ok, you may be asking yourself, “Why even go though all this trouble of printing on Tyvek at all?” I began asking myself the same thing and so released the white version… the color natural Tyvek starts out as.

Or why not make wallets from something that stays looking new for longer? How about custom making a material that stays looking new for years, outlasts leather, and is still super thin? No worries- I’m on it.

Thanks to all the customers who provided images of their wearing patterns and several who even sent theirs back to us for inspection. There were a few repeat customers whose feedback was especially valuable because we could look back in time to see what their first one looked like compared to the more recent ones. They essentially provided data for a “within” subjects study with more powerful insights from just a few people. The richness of those information from those customers was ultimately what led us down the right path.

This is a reminder that making products isn’t always a steady upward path of progress… even when you’re just trying to make more of something that was previously produced.

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