Foam Lamination Creates Custom Foam Composites for Many Applications

Foam lamination is a process that creates flexible foam composites from a wide variety of materials:

  • Foams
    • Polyurethane
    • Polyethylene
    • Vinyl-nitrate
    • EVA
  • Outer/inner layers
    • Fabrics
    • Films
    • Non-wovens
    • Adhesives

The composites are then put to work across a range of industries for a wide assortment of products:

  • Die cut promotional products – “We’re #1!”
  • Beverage insulation products
  • Intimate apparel
  • Disposable medical padding and bandages
  • Safety equipment
  • Costumes
  • Protective helmets
  • Saddle pads
  • Gym mats
  • And many more….

Dal-Bac manufacturing has been creating custom foam lamination solutions for over 25 years and we specialize in creating new solutions and processes that deliver exceptional value. Central to our success is our engineering department and extensive supplier network.

Our engineering team works closely with our customers to create specifications for the final foam composite. We start by clearly understanding your needs and defining any specific features that may be required including:

  • Overall thickness of the final composite
  • Padding capability
  • Flexibility and stretch
  • Breathability
  • Durability
  • Comfort – including the composite’s “hand”

With all the requirements in hand we work with our supplier network to identify and source materials and then develop the foam lamination process:

  • Flame Lamination – This process allows us to create double-sided composites where the foam is sandwiched between a combination of decorative or technical materials. A key benefit of flame lamination is that it eliminates the need for adhesive and the risk of adhesive creep and bond failure.
  • Thermal Fusing – allows us to bond flexible materials in a continuous roll-to-roll manner. By carefully controlling temperature, pressure and dwell, and selecting the best adhesive solution, we create strong bonds between foams and target materials to create bonds that stand up under any environmental extreme.

We are known for utilizing custom elements and processes to make sure our foam lamination solutions exceed your expectations. As an ISO 9001: 2015 certified company we are dedicated to continuously improving our processes and systems to insure that we exceed your expectations.

If you have a foam lamination challenge – Dal-Bac is ready to solve it for you. Contact me to start a conversation:

Ruben Duran
rduran@dalbac.com
469-689-0964

Flame Laminating is Fast, Efficient, and Customizable

Dal-Bac Manufacturing has over 40 years of experience using Flame Lamination to create single-sided, double-sided, or multi-layered composites for a wide range of industries.

Flame lamination is a proven technology for creating strong bonds between flexible foams and a variety of substrates including fabrics, films, and papers. Our flame lamination services deliver a broad range of benefits:

  • Speed – Flame lamination is a proven process that generally delivers much faster production speeds than other laminating options.
  • Efficiency – Flame lamination does not require adhesives, which reduces material costs.
  • No bond failure – Flame lamination results in strong bonds between all layers of the composite without the risk of adhesive creep or bond failure.
  • Better products – Flame lamination can enhance product characteristics by improving durability, adding breathability, creating a moisture barrier, adding thermal and acoustic insulation, and more.
  • Custom solutions – Our engineering team can work with you to create a custom solution for your specific product challenge.  Solutions include both materials and process adaptations and innovations to meet your specific need.

We are committed to exceeding our customer’s expectations and to achieve that we provide samples and develop prototypes for projects. We also use test runs for new products to make sure that the finished product meets all specifications prior to actual production. If you have an existing product we will work with you to improve the production process to increase your yield and lower your costs. I

If you have a need for flame lamination services please consider Dal-Bac. We are an ISO 9001 certified company that is dedicated to the success of our customers. Our combination of engineering capabilities, process and product innovation, and a comprehensive supplier network insures that we live up to our mission of exceeding your expectations.

ISO Certification means superior Lamination, Coating, and Thermal Fusing Solutions for You.

Dal-Bac has been ISO 9001 certified since 2013 and we are one of the few companies in the textile industry to have ISO 9001:2015 certification. The reason we do this is simple – it helps us achieve our core value of exceeding customer expectations.

The International Organization for Standardization (ISO) creates global standards that ensure that materials, products and services are correct for their purposes. The central pillar of the ISO 9001:2015 standard is a commitment to a process that strives for excellence and continuous improvement.

To achieve ISO 9001:2015 certification a company must demonstrate:

  1. A clear understanding of their customer’s requirements
  2. A commitment to a process approach to govern materials, products, and services
  3. An active program to drive improvement in both processes and final results

What this means for our customers is that Dal-Bac:

  • Has a keen interest in understanding your business and is dedicated to finding, and improving, the best solution to meet your requirements.
  • Maintains an extensive and growing supplier network to offer the best available materials and to help find innovative ways to improve the production process and the quality of the finished product.
  • Has a disciplined process management system designed to drive continuous improvement in all phases of product design and production. One of our key objectives for our customers is to reduce costs and improve yields by deploying process and material improvements.
  • Utilizes a rigorous Quality Management System that includes quality checkpoints throughout the production process and helps identify areas of possible improvement or innovation for exploration by our engineering and manufacturing teams.

The result of our commitment to ISO standards is that we deliver exceptional quality products tightly designed to exceed expectations and to increase your overall customer satisfaction. Our ISO 9001:2015 certification covers all of our key product lines:

The bottom line is that being ISO 9001:2015 certified makes us a better partner for our customers. It helps us reduce risks, improve our processes, provide innovative solutions and focus on improving results for you.

Please contact us to see how our ISO 9001:2015 certification can make a difference for your business.

Pressure Sensitive Adhesives, Anti-Fog Coating, and More with Advanced Coating Technologies

Dal-Bac Manufacturing provides advanced coating technologies across a variety of industries including automotive, medical, sports, textiles, and construction. Our advanced coating technologies include both solvent and water-borne coatings across a wide variety of substrates.

We utilize Meyer Rod, Knife-Over-Roll, and Pattern coating to produce our coating solutions. Our technical and engineering teams are the keys to creating successful coatings for our customers as they allow us to:

  • Research, test, and identify the best coating solution for the specified substrates
  • Research, test, and identify the best combination of substrates and adhesives to exceed performance requirements
  • Create, improve, or customize the coating application process to meet specific performance requirements
  • Create custom adhesive formulations to meet the unique requirements of a specific application

Dal-Bac is an ISO 2001: 2015 certified company. ISO certification requires commitment to exceeding customer expectations and continuous improvement in process and product quality. That commitment is the foundation of our advanced coatings technologies solutions.

We understand that testing during the application process and after the application process is critical to delivering accurate coatings with exceptional quality. That is why we constantly seek to improve our process and add additional tools to insure accurate application, exceptional performance, and the highest quality.

A great example of this is the addition of a Keyence sensor to our wet coating production capabilities. The Keyence sensor lets us:

  • Control coating weights
  • More accurately measure for improved application performance
  • Apply and measure thinner layers of coating
  • Generate real time data for coating applications immediately after adhesive deposition
  • Improve production process and quality control on a continuous basis

We rely on our proven process to make certain that our advanced coatings technologies will exceed your expectations for performance, quality, and cost. Our engineering and process teams work with our customers to make certain that all substrates and coatings are exactly what are needed to meet specific requirements.  Our advanced coating technologies include Pressure Sensitive Adhesives, Anti-Fog, water-borne, and solvent coating applications. We also provide custom coating formulations to meet unique customer needs.

Dal-Bac knows Automotive – Lamination and Thermal Fusing Solutions

Dal-Bac Manufacturing Company, Inc. has a long, successful history of supplying composite materials for the automotive and trucking industries. Our automotive products are manufactured with lamination and thermal fusing solutions. We are accustomed to exceeding the exacting standards of the automotive industry.

Dal-Bac Automotive composites are used in a broad range of applications including:

  • Protective covers for cars, trucks, and recreational equipment
  • Heated and cooled seating systems
  • Headliner fabrics
  • Floor protection
  • Upholstery
  • Soft interior surfaces

Our solutions are designed to improve comfort, appearance, durability, safety, and value. For example, we partnered with one of our customers to create a new kind of thermal/acoustical composite that delivers superior performance for temperature and sound control. We utilized
thermal fusing to create an insulation that used as much empty space within itself for improved insulating performance and lower weight. Our engineers then went beyond the product specification to develop an innovative production technique to significantly reduce the material requirements of the final product and significantly lower the production costs. Learn more about this innovative approach in our case study.

Automotive composites are used in a wide variety of applications but all of them have requirements for durability, comfort, and appearance. Dal-Bac creates customized solutions to meet specific needs including:

  • Stain resistance
  • Water resistance
  • Insulation capabilities
  • Breathability
  • “Hand” – product tactile profile

Our favorite thing is working with our customers to develop improved solutions for their specific needs. Our team of engineers is dedicated to finding new solutions and improving the performance of existing composite solutions.  We constantly evaluate materials and processes in search of ways to increase output and lower costs.

Our Texas location makes Dal-Bac a great partner for the growing automotive manufacturing operations in the Southwest and Mexico. We love solving challenges for our automotive customers that create superior performance and cost efficiency. If you need a new solution for automotive composite materials or better performance for an existing product we can help you with both.

Dal-Bac Manufacturing Proudly owned and operated in USA

Dal-Bac Manufacturing is a USA based provider of critical soft goods conversion services including flame lamination, thermal fusing, PSA Coatings, and additional services including die cutting slitting, and narrow screen web printing. All of our products are 100% manufactured in the USA.

In this uncertain time, having a reliable domestic source for conversion products reduces the risk of production and delivery delays inherent with COVID 19 challenged international supply chains. All of our production takes place in our Forney, Texas plant located just east of the Dallas-Fort Worth Metroplex. Our central location gives us easy access to our network of suppliers and the ability to service customers across the United States.

We have a large network of raw material and component suppliers with both domestic and international relationships. We do recognize that many companies are seeking to add “Made in America” to their products, which requires all components of the product to originate in the United States. Our domestic supplier network insures that we can access the domestically produced materials you need to meet the “Made in the USA” requirements.

With the uncertainty and time delays of international commerce caused by the global pandemic, many companies are looking for domestic solutions for their material needs.  If you are looking to re-shore or find a new source for your materials our technical team is standing by to assist you. We can help you meet your current needs as well as work with you to develop more efficient and innovative options.  We understand that time, costs, and maintaining quality are all critical elements and are dedicated to developing processes that increase yields and lower costs for our customers.

If you are experiencing challenges meeting your needs for laminated flexible textile products, Dal-Bac can help with production in the United States and can supply 100% USA produced materials to create your products.

Call us at 469-689-0964 and let’s talk about how we can help you.

Excellence in Lamination Services

For over 40 years Dal-Bac Manufacturing has specialized in laminating flexible materials into component parts, production stock, and final products for a wide array of customer applications. We convert foam, fabrics, papers, plastics, films and more via Thermal Fusing and Flame Lamination.

Our North Texas location allows us to easily service customers throughout North America while providing exceptional access to suppliers in North America, Central America, and other countries. We have been building our supplier network ever since we opened and are able to source proven materials and create new options with our trusted partners with exceptional quality.

Dal-Bac is an ISO certified company, which means we are dedicated to exceeding customer expectations. We work closely with our customers to develop solutions that result in lower costs and higher yields for their products. Our keys to exceeding expectations include:

  • Our Engineering team who generates superior performance by working with customers to create new solutions for their applications, design and optimize production processes, and source new material options.
  • Our Quality Assurance team who ensures quality standards are met throughout the production process and who play key role in our commitment to improve our systems and processes to lower costs and increase yields.
  • Our Customer Service team who quickly responds to all customer requests, concerns and questions.

Our range of services, supplier network, and commitment to exceed customer expectations has resulted in Dal-Bac becoming a trusted partner across a variety of industries including:

  • Advertising and Promotional products
  • Automotive
  • Clothing
  • Medical
  • Packaging
  • Sporting Goods
  • Upholstery

We have the expertise, manufacturing processes, customer service, supplier network, engineering skill and commitment to customer success to improve or create solutions for our customers. Please consider a conversation with us to find out how we could help you with exceptional conversion solutions.

Ruben Duran
rduran@dalbac.com
Account Manager
972-562-6400

Happy Holidays From Dal-Bac and Dallas Bias


Happy Holidays


2020 has been a challlenging year for everyone and we are even more thankful than usual for our teammates, suppliers and customers. We are proud that we have been able to continue to exceed our customers expectations this year and are looking forward to a much brighter 2021 for all of us. Thank you for your support and partnership and best wishes to you and your loved ones for this Holiday Season and the New Year!I 

Happy Holidays from all of us at
Dallas Bias and Dal-bac Manufacturing.

Happy Holidays and 2020 Holiday Schedule


Happy Holidays from Dallas Bias
and Dal-Bac Manufacturing Company!

Our staff and families are wishing you and your family the happiest of Holiday Seasons. We also want to take the opportunity, at this special time of year, to thank you for working and partnering with us.

2020 HOLIDAY SCHEDULE
Here’s a quick reminder about our holiday schedule:

THANKSGIVING WEEK
Thursday November 26, 2020 CLOSED
Friday November 27, 2020 CLOSED

CHRISTMAS
Our office and plant will be closed on Christmas Day, December 25.
Manufacturing operations will be shut down from December 25 through January 1.

NEW YEAR’S WEEK
Monday, 28th of December – Thursday, 31st our office we will be OPEN.
Friday, January 1st our office and plant will be CLOSED. 

We will return to normal hours on January 4, 2021.

We will still be receiving your purchase orders via email at:
orders@dalbac.com and orders@dallasbias.com

Please feel free to contact us at 972-564-6200 and 214-824-2036.

We appreciate your business. Happy Holidays from all of us at
Dallas Bias and Dal-bac Manufacturing.

The Dal-Bac Story

Since 1973, Dal-Bac Manufacturing Co., Inc. has been supporting their customers with a variety of converting capabilities serving many industries.In the beginning our primary operation was solvent and pressure sensitive coatings for the apparel industry. 

Franz Duy, owner and President and Max Kipness, owner of Dallas Bias Manufacturing, purchased the company in 1978. Our vast experience in the apparel trade industry allowed us to expand our capabilities into flat bed fusing, flame laminating, narrow web weaving and printing as well as die cutting. 

Our journey has given us experience in many different markets including orthopedic, advertising specialty, automotive, building trades, apparel, and appliques.

Our desire today is the same as it has been for the past 42 years; we value all of our customers and potential customers and work with each one to find how we fit. Once we establish a fit, we work diligently to create a cost effective, high quality product. We have a strong staff devoted to the engineering and service necessary to establish and maintain long term partnerships.

Dal-Bac Manufacturing was awarded the ISO 9001:2008 certification in the spring of 2013. On June 23, 2016, we were awarded certification to the most recently revised ISO 9001:2015 revision. These achievements demonstrate Dal-Bac’s ongoing commitment to world class quality performance in providing products to our customers.

Over the years we have grown from 4 employees to over sixty and from 12,000 ft2 to 120,000 ft2 of manufacturing and warehouse space. In 2020 we merged with Dallas Bias to enhance our capabilities and better serve our customers.

Let’s start a conversation about how we can help you!

Ruben Duran
rduran@dalbac.com
Account Manager
972-562-6400