Dal-Bac Manufacturing offers
a full range of lamination services including Thermal Fusing. Our thermal fusing solutions combine two or more
materials together into a single composite. We use thermal fusing lamination to
create finished products that combine the characteristics of the individual
layers and have enhanced durability and performance in a wide range of
environmental extremes. Thermal fusing lamination is ideal for combining
- Plastic films
- Waterproof textiles
The most critical part of any thermal fusing lamination project is
selecting the correct adhesive. To make sure we select the correct adhesive,
our engineering team works closely with our customers to make sure that we
understand the bond requirements for the finished product. Our thermal fusing laminations use one of two
types of thermoplastic adhesives:
films: Plastic films that have been
engineered to melt at a specific target temperature and that exhibit superior
flow characteristics upon melting.
web adhesives: These are conventional
hot-melt adhesives that are melted and spun onto a belt, creating a thin
continuous web of hot-melt adhesive.
Another factor in selecting the adhesive is
understanding where and when the adhesive will be fully activated. There are two
- The project involves creating a finished product consisting
of one or multiple layers of materials bonded together for use in downstream
production. In this case the adhesive is
fully activated creating the final composite product.
- The project requires that adhesive be added to a material
but not fully activated. The adhesive will be reactivated at a later production
stage to create bonds between the original material and other surfaces.
Dal-Bac is dedicated to meeting and exceeding
exacting manufacturing specifications. That is the commitment and dedication we
demonstrate with our ISO 9001:2015 certification.
If you have a need to combine thin, flexible
materials for either a product component, final product, or downstream
application our team can help you develop the best solution.
Foam lamination is a process that creates flexible foam composites from
a wide variety of materials:
are then put to work across a range of industries for a wide assortment of
- Die cut promotional products – “We’re #1!”
- Beverage insulation products
- Intimate apparel
- Disposable medical padding and bandages
- Safety equipment
- 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:
thickness of the final composite
– 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:
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.
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:
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:
lamination is a proven process that generally delivers much faster production
speeds than other laminating options.
lamination does not require adhesives, which reduces material costs.
bond failure – Flame lamination results in strong bonds between all layers
of the composite without the risk of adhesive creep or bond failure.
products – Flame lamination can enhance product characteristics by improving
durability, adding breathability, creating a moisture barrier, adding thermal
and acoustic insulation, and more.
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.
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:
- A clear understanding of their customer’s requirements
- A commitment to a process approach to govern materials, products, and services
- 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
- 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
- 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.
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
- 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.
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
- Heated and cooled seating systems
- Headliner fabrics
- Floor protection
- 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
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
- Stain resistance
- Water resistance
- Insulation capabilities
- “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
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.
Manufacturing is a USA based provider of critical soft goods conversion
services including flame
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
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”
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
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
- 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
- Sporting Goods
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.