Brad’s work with Signs.com has included an array of signage, including a 108 x 108-inch fabric banner scoreboard, multiple yard signs, aluminum signs, and more.

Tell us about yourself
I’m one of two partners in Valley Design & Manufacturing in Millersburg, Ohio. I have been involved in the furniture-manufacturing industry since 2003. Since that time, I have worked in various capacities with companies in the same or similar markets. In 2016, I began to build a solid team of passionate individuals with varying talents (and personalities) who understand this industry inside and out.

What does your company do?
Valley Design & Manufacturing domestically manufactures furniture and fixtures primarily for the restaurant and hotel industries. Our disciplines include fabrication in wood, steel, glass, and upholstery, and usually a combination of those mediums. Our clientele includes major hotel chains, boutique hotel developers, and mid- to high-end restaurants. We have also supported many public-amenity spaces in high-rise living facilities and global brands with their store fixture needs. We have increasingly been introduced during the project design phase to offer our expertise on best-use material selections, manufacturing efficiencies, sustainable finishes for constant sanitizing, and cost-saving processes.

Where did the idea of your company come from?
I have either been self-employed or in an operations position since 2003, so being an owner was the logical next step for my personal ambitions. A previous company that I worked for had a great vision for commercial and hospitality furnishings industry, and we grew that company exponentially in a short amount of time. By 2014, however, I felt that company had lost sight of what made us “great” and I left that company for a new path. In 2016, I began to assemble the team we have now; Lester Miller, who I worked with at the previous company, was able to come on board in 2017 as our operations lead and became a partner this year.

Each team member and partner with Valley Design & Manufacturing has a specific role and a specific process to deliver the best experience to the client as possible. We’re very forward-thinking in our use of technology, yet rely very heavily on the business relationships that we develop to increase our market impact.

What is one thing most people don’t know about you?
While our warehouse/logistics operation is located just outside of Millersburg, about an hour south of Akron, we also have a studio in historic Roscoe Village in Coshocton County. Our studio is on the “Canal Level” of the original Roscoe General Store next to the former Ohio & Erie Canal. The building is more than 150 years old and still has the original timbers, sandstone, and bricks from the late 1800s within our space. It has been amazing to be on so many high-profile projects in major metropolitan cities and yet come from such a quiet part of the country. It’s interesting to explain to our clients where our team is located – and why it’s hard to find on a map of Ohio!

Hands-On, Forward Thinking

What sets you apart from your competition?
We are very hands-on, and we’re personally engaged with all aspects of marketing and sales. My responsibility is to showcase our company’s talents and work with our team to deliver an outstanding experience to our clients and consultants.

As I mentioned earlier, we are very forward-thinking when it comes to technology. Since the vast majority of our supply chain/vendors are part of the Amish community in nearby Holmes County, the need to have a cloud-based ERP system for our own communication became a necessity. We invested in a system so that everyone on our team could immediately be up-to-date and informed on any information relevant to the production process: For production, we can see the physical movement of material from one process to another; client facing can track on-time status; financials are always at our fingertips, etc.

Other tech we employ includes: a cloud content-management platform paired to our ERP system, for all of our client folder management needs – giving everyone instant access to drawings, approvals, project details, and photos; advanced 3-D software resulting in some of the most robust client and shop drawings in the industry – our renderings are near photo quality and every detail is available for review by our team and our clients; and we never miss an opportunity to apply automation to any of our manual fabrication or finishing methods.

How do you market your business?
Our main marketing tool is simply relationships. From there, word-of-mouth and repeat clientele continues to expand our network of designers, consultants, developers, and corporate brands. We also feel that a great website is important as a reference tool, and we plan to make our website more robust in the future with case studies focusing on our clients.

How do you “wow” your customers?
We always deliver more than what we promise!

What are one or two strategies for gaining customers that you have been successful with?
When we are brought onto a project that has a new designer, architect, etc., we make it a priority to meet with that team face-to-face. Having that time to explain our process and our capabilities creates the greatest level of communication going forward.

How do you compete with bigger competitors?
Our team never loses the drive to be better. Our ability to make decisions, pivot, and react to changes in this market is key for us. Our business model is unique, and it allows us to compete with any size company, including overseas companies, without the exhausting overhead of “big” companies.

Never Taking the Team for Granted

What is one of the biggest challenges you have had with your business – how did you overcome it?
Our biggest challenge has been the impact of COVID-19 on the hospitality industry. However, we have been able to stay fully operational with smaller projects through this year – so we’re in a great position as the country begins to return to normal.

If you were to start again, what would you do differently?
Our primary market was New York City, including some of the most iconic and high-profile locations in Manhattan. We had expanded our footprint into Nashville and South Florida at the end of 2019. If we were to do anything differently, it would have been to establish ourselves with a much larger footprint in more markets.

What is the one thing you would do over and over, and recommend everyone else do, too?
Built the best team possible – and never take them for granted.

Is there a book that you recommend our community should read?
The Forgotten Man, by Amity Shlaes. The impact of the individual is underestimated.

Lessons Learned

Can you speak to your growth to this point? Why you think it will continue?
We are very optimistic about our position in a post-COVID economy. We experienced more than a 100% growth from 2018 to 2019, and we were poised to do the same in 2020. Our team has remained intact and the lessons we have learned this year will impact our financial decisions for the future of our company.

Where can you be found on the internet?
You can find us via our website, at www.valleydesignandmfg.com.

Small Business Success Story: Valley Design & Manufacturing

Banners can benefit from having an edge as well. An edge finish – aka hem – will provide your banner with increased durability and a more pleasing appearance, whether the banner is fabric, mesh, or vinyl.

Here, in this edition of “Signage 101,” we’ll take a look at the basics of edges for banners: the tools used to hem/edge, how we tackle banner edging here at Signs.com, other banner options (including no edge at all), and we’ll finish up this primer with some notes on grommets and pole pockets.

Sewn Edge for Fabric & Mesh Banners

If it’s a fabric or mesh banner you’re creating, a sewn – aka “stitched” – edge or hem is the way to go. The stitching reinforces the edges of the banner to add to its robustness while also generating a clean, professional aesthetic.

It’s worth emphasizing here just how much a banner’s durability can benefit from the addition of a good edge. The edge gives a supporting structure to the banner – and, so, more strength – enabling it to better withstand any challenging conditions. Yes, vinyl will, by its very nature, hold up better than fabric in stressful environments, but you’d be surprised how much a fabric banner will benefit from a skillfully done edge. Plus, a sewn edge will typically last the lifespan of the banner itself.

Keep in mind that sewing a banner intended for commercial use requires some “industrial-strength” tools and materials – well beyond the needle and thread your mother probably used when darning your favorite childhood sweater or injured teddy bear. Let’s take a look at some of these.

The primary tool to produce a stitched edge: the sewing machine. As noted above, however, this is a brawnier version of the home or craft version you’ll find at your local Walmart. Industrial sewing machines typically have a higher percentage of metal parts (vs. plastic) than their consumer cousins, plus they boast larger motors, can achieve higher speeds, and tend to be more maintenance free. Importantly, they can take on the heavy-duty repetitive tasks required of them while still producing nicely finished seams. As you might guess, there are industry- and task-specific industrial sewing machines. And some operations make use of a serger – this is a version of an industrial sewing machine that also cuts the fabric as it stitches.

Of course, every sewing machine needs a needle. For industrial purposes such as banner sewing, the needle must be strong enough to accommodate heavyweight threads and materials, as well as the aforementioned speeds and stress of repetition. Made from high-quality metals, these needles come in sizes ranging from approximately 0.35 to 2mm thick, with most being in the 0.50 to 1mm range. Just like with sewing machines, there are needles designed for specific applications and industries – such as book bindings, car seats and airbags, and shoe manufacturing (think about how sturdy a needle must be in order to process a shoe sole!).

Last, but certainly not least, there’s the seam thread itself. It’s important that the thread not only be strong but will also hold up to whatever might be thrown its way. Without getting too deep into “thread tech” here, threads can be made from either natural fibers or synthetic fibers (or a combination of these); they are then spun into the final product using a variety of construction methods.

For example, a twisted multifilament polyester thread – which is what we utilize here at Signs.com – is made by twisting together continuous filaments of polyester into a bundle. The filaments are then layered together to make the thread, which is colored, stretched, heat-set, and given a bonded finish. Our multifilament polyester thread is heavy-duty (tex 90) and is both UV- and abrasion-resistant; it’s been designed for long-term use.

Signs.com offers a high-quality sewn edge (with white threads) on both our fabric banners and our mesh banners; there is no charge for this service.

Welded Edge for Vinyl Banners

Heat welding an edge provides you with the strongest option for vinyl banners, which are typically used for exterior applications (but can be used indoors, too). A welded edge not only prevents any fraying, but it also ensures that the banner maintains its shape and helps prevent any stretching that might occur.

Of course, many people hear “weld” and can’t help but think of metal arc welding – complete with an acetylene cutting torch and full helmet. Or maybe you’ve simply seen the opening scene from Flashdance one too many times.

But welding vinyl banner material is quite different. For vinyl (or other plastics), welding options can range from hot air welding and impulse welding to radio frequency (RF) sealing and more. Generally, the technology being utilized has to do with which weld type is necessary for a particular combination of materials and applications.

We use hot wedge welding for our banner seams/edging at Signs.com. Basically, the process breaks down like so: Using a hot wedge welder machine, we position the heated wedge (with a temperature ranging from 700F to 920F) at the weld point to provide the heat, softening the material. The vinyl is then pulled across the heated wedge and pressure is applied. This combination of very precise heat, speed, and pressure joins the vinyl (or other material) to produce a weld that’s extremely strong, consistent, and, importantly, ensures that the banner doesn’t fray or tear if demanding conditions should arise. The result: a smooth, finished edge that nicely complements your vinyl banner.

At Signs.com, our welded edges are free; there’s no additional cost to edge your banner. However, while we do offer a welded edge for our 13-oz. vinyl banners, we don’t offer this option on our 18-oz. vinyl banners – the resulting thickness of the vinyl material would produce a very thick edge, and would lessen the banner’s overall visual appeal. So, for our 18-oz. vinyl banners, we offer a flush cut (see below).

Flush Cut and Other Options

You can also choose to not have any hem or edge finish on a banner – this is referred to as a “flush cut.” Here, the banner is cut to the same size as the design.

Flush-cut banners typically work fine if you’re not going to hang or otherwise suspend your banner. In this case, because there won’t be all that much stress on the edges, it’s unlikely the banner would experience any edge fraying. So, if your intention is to simply lay your banner flat on a table or other surface, or perhaps if the banner is to be inserted into a frame, stand, or system, then a flush-cut banner can work quite nicely.

Also, if it’s a heavyweight 18-oz. banner you’re producing, you don’t really need an edge finish or hem. In fact, as we noted above, flush-cut is the only available option for an 18-oz. banner here at Signs.com, whether the banner is single-sided or double-sided. Why? Because the vinyl’s thickness would result in an overly thick edge if a hem was added, weakening your banner’s overall aesthetic; plus, it’s important to note, the 18-oz. material is unlikely to fray when flush cut. You can, of course, add grommets and/or pole pockets to our 18-oz. banners (as well as to our 13-oz. banners). As with a welded hem, producing a flush cut on your banner is free of charge here at Signs.com, and can be changed as needed on our design tool during the design process.

We sometimes get asked about other options when it comes to adding an edge finish to a banner – alternatives such as tapes, glues, and chemicals.

Industrial-strength tapes are available and some of these tapes, when used correctly, can approximate a weld. But be wary of tapes that are intended for short-use or non-industrial applications – these can peel under harsh conditions, limiting the adhesion. So, depending upon the type of tape used, it’s unlikely to hold up quite as long as a weld.

The same goes for glues and chemicals: Industrial-strength varieties can essentially mimic a weld, enabling the faces of the vinyl to fuse together. But they can also be messy when applied, which isn’t great for the banner’s appearance. In addition, the glues or chemicals must be designed for PVC vinyl; otherwise, you won’t get a good bond to the surface and the adhesion will be lost over time.

In our opinion, a well-sewn, stitched edge or a professional welded edge will provide a banner with superior overall performance.

Fence Banners, Grommets, and Pole Pockets

Now, a few words are probably in order here regarding fence banners, grommets, and pole pockets.

Fence banners: Our custom fence banners (aka fence wraps, screens, or coverings) are available in either 9-oz. vinyl mesh or 13-oz. solid vinyl versions. Most commonly placed on chain-linked fences, they can also be applied to any other type of fence or wall, and they’re primarily used for outdoor applications such as construction sites, schools, sporting sites and events, and concerts.

Just as with standard banners, the high-quality finished edges on our custom fence banners are produced by either sewing (mesh) or welding (solid vinyl). However, you also can add an optional reinforced edge on our custom fence banners – we sew an additional layer of nylon webbing material along the banner’s outer edges, which adds considerable strength to the banner edge and helps protect the banner from tearing in windy conditions or other severe weather. The webbing is folded into the hem, so from both the sides and front the result is a very clean finished product This option is available on both mesh and 13-oz. vinyl banners.

Grommets: Inserted into the material of the banner, grommets are 3/8-inch metal rings that are brass in color and enable you to use ropes, clips, or zip ties to hang your banner, attach it to a fence, etc. Our automatic grommet machine can cut a hole in just about any material (even aluminum sign board and Kevlar!), and we use it to make grommets available on our fabric banners, mesh banners, and vinyl banners (13-oz. as well as 18-oz.). For our fence banners, it’s important to point out, we use a larger and heavier-duty grommet especially designed to go through the extra-strength webbing (our standard grommets won’t handle the extra thickness that this webbing adds to the banner).

For all of our banners, we can add grommets every 12-18 inches, every 18-24 inches, every 2-3 feet, or in the banner’s four corners. Keep in mind that if you choose to have grommets inserted into your banner, you cannot also add pole pockets (see below). Grommets are free on fabric, mesh, and vinyl banners at Signs.com. Looking for more information about grommets? Check out our in-depth Signage 101 blog, Grommets and Your Sign.

Pole pockets: As the term indicates, sewn pole pockets allow you to insert poles into your banner to display it – enabling you to take your message mobile. Made of the same material as the banner, the 3-inch pole pockets are sewn using industrial-strength thread (see above) and can be added to the top and bottom of the banner.

We offer optional pole pockets on both our 13-oz. and 18-oz. banners. Compatible with single-sided as well as double-sided banners, pole pockets will leave a flush-cut edge. And as noted earlier, if you choose to have pole pockets, we cannot also add grommets to the same banner.

Basking in Banners

One of the most versatile sign types, banners can be utilized in countless ways – to advertise your business, announce a grand opening, promote a new product at a trade show, celebrate a holiday, direct people to the farmers market, trumpet the arrival of a newborn, proclaim your support for first responders, and much more.

For whatever purpose you’re producing your custom banner, rest assured that here at Signs.com we can answer any questions you have regarding your edge finish. Plus, we can help you out with any other signage concerns or challenges you might be facing.

Related Articles

Standard Vinyl Banner Sizes – Signage 101

Common Uses For Retractable Banners

A Guide To Outdoor Banners – Signage 101

Give Your Banners an Edge: Signage 101

While you’re exploring banners, check out our blog posts on how to hang your banner or the different banner finishing options available.

Vinyl Banners

Vinyl banners are the most durable and commonly used banners for outdoor display. You can choose between the standard 13 oz. or the thicker 18 oz. vinyl to print on, depending on your intended use. Typically, the heavier the material, the greater the durability.

The 13 oz. vinyl is your best bet for everyday display. This banner is impressively durable and versatile, and it is the same material used for billboards. On the other hand, 18 oz. vinyl is meant for heavy-duty display like at construction sites. Regardless of weight, vinyl banners offer exceptional image quality and display versatility.

Vinyl comes with a semi-gloss appearance, which can be noticeable when light shines on it. Avoid placing banners in direct light to reduce visible glare; the less glare there is, the better readability your vinyl banner will have.

Since vinyl banners are heavier than fabric or mesh, place grommets around the edges of your banner in addition to the four corners to ensure it is pulled taut when displayed. Another way to display a vinyl banner is by using pole pockets, which help you suspend the banner from a pole or from rope.

Fabric Banners

Fabric banners are designed for both function and aesthetics by presenting beautifully printed images on a high-quality canvas. Their lightweight polyester material allows them to be easily transported and displayed, making decorating for events a breeze.

Fabric banners are slightly transparent, which means displaying them in front of windows or light sources will allow light to illuminate through the material. They’re also meant for indoor use, though displaying outside is possible as long as you avoid doing so in heavy rain or wind. Fabric banners are typically displayed by hanging them from a ceiling or awning; you can use grommets or pole pockets to hang your banner.

Mesh Banners

Functionality is the name of the game for mesh banners, and they perform especially well when used outdoors as they boast wind resistance and a semi-transparent effect.

Mesh allows wind and light to pass through without compromising the quality of the printed design. It’s important to note that the colors and graphics on these banners are often described as “lighter” or “muted” compared to their vinyl and fabric counterparts. Mesh banners are also best viewed from a distance, an important consideration when creating your artwork.

The 8 oz. PVC mesh offers exceptional tensile strength while preserving its lightweight form. The mesh pattern on these banners has a ratio of 70:30, meaning that 70% of the banner is actual material, whereas 30% is made of tiny holes. Mesh banners also come with hemmed edges to ensure the material does not tear when pulled taut during display.

Mesh banners work great on chain-link fences; they help emphasize the semi-transparent nature of the mesh pattern and allows you to display a design without completely blocking out the surface and the background. To install your mesh banner on a chain-link fence, use grommets, short ropes, or zip ties, as they make it easy to attach your banner to the fence at multiple points.

What is the Best Material for Outdoor Banners?

Vinyl banners are perfect for outdoor banners and signage. They are versatile, weather-proof, and UV-resistant, which means they last longer outdoors without fading or getting ripped or torn. You can hang them anywhere, making them the best option for outdoor signage. But if you’re installing banners in windy locations or for the purpose of maintaining privacy, use mesh banners.

What is the Best Material for Indoor Banners?

Fabric banners are designed for indoor display. We can’t praise enough the impressive color and details of printed designs on fabric banners. Pictures don’t do them justice but here’s a few examples of fabric banners in their natural habitat to show you how brilliant they are.

Which Banner Material Should I Choose?

We put together a simple chart below to get a quick comparison of each of our banners and a summary of the information we have discussed.

A Custom Choice

Regardless of your banner choice, all banner types are customizable; your design will be printed to impress! Need help making that eye-catching design? Our free design services can help you realize your vision! If you still need some assistance in choosing the right banner for your needs, give us a call at 888-222-4929.

Related Articles

Why Vinyl Banners Are Reliable Everyday Displays.

Designing a Step and Repeat Banner: Signage 101.

How To Remove Wrinkles From Vinyl Banners – Signage 101.

Signage 101 – Banner Material Comparison

How Is Denier Measured? And What Is It Measuring?

Simply put, the denier count for a piece of fabric equates to how much an individual thread from that fabric would weigh in grams if that thread were to be 9,000 meters long.

Before we get ahead of ourselves, it’s important to note that manufacturers present denier count in one of two ways:

The most common format you’ll see denier represented is as a whole number preceding the lowercase letter “d”. For example, if you are looking at a material that is 300 denier, it would be listed as 300d.

Another way a manufacturer might present denier is two separate whole numbers, which represent the thickness of threads going in the machine direction (known as “warp”), by the thickness of the threads going in its cross direction (or the “fill”), respectively. For example, a 600d material would be listed as 600×600 denier. So to be clear, a material that is listed as 50×50 denier is the same as 50d, since all of the threads (both the warp and the fill) are the same thickness.

To better understand how the measurement for denier works you can refer to this equation:

1 denier (d) = 1 gram in weight for every 9,000 meters of thread length

To help put it in perspective, take a look at each thread in the image below. Notice how each thread has the same length yet differs in thickness. The thicker threads will weigh more than the thinner threads, as they consist of more material. Thus, threads that weigh more have a higher denier count than those that weigh less. Threads such as the ones shown below are then woven together with other threads of the same thickness to create materials such as fabric banners, shirts, tents, flags, & more.

So what does that all mean for the material you are looking at? Let’s use a standard t-shirt as an example. The t-shirt is made up of many threads woven together. If the t-shirt was 30d (30 denier) than that means each thread used to create that t-shirt would weigh 30 grams if that thread were to be 9,000 meters in length.

High vs. Low Denier Count. Which Is Better?

So you’re looking to get some signage and want to know which denier count to go with. Is it better to have something with a low denier count or a high one? Well, it depends.

Generally speaking, the higher the denier count, the more durable the material will be. This is due to the thicker threads used to make up the material. So, if you’re looking for something that is durable and can withstand outdoor wear and tear, you want to go with the highest denier material possible.

This is why you will see outdoor materials such as flags, pop up tents, and banners with denier counts ranging anywhere from 150-1,000d. Once denier counts start getting into the hundreds, you start seeing materials that are extremely durable, tear-resistant and abrasion-proof. It is also important to note that tensile strength (resistance to the material breaking under tension) increases with the denier count. Banners, for example, are designed to withstand tension up to 154×17 lbs/inch, which is more than enough tensile strength when hanging the banner with four corner grommets.

If you are more concerned with low weight and smoothness, you will want to go with a material that has a lower denier count. The lower the denier count, the less the material is going to weigh as a whole and the finer that material will be. Benefits of having thinner material usually include a reduction in cost as well as ease of storage and transportation (due to the low weight of the material). This will, however, lead to the material becoming more prone to tearing.

It is also important to note the amount of light certain materials will allow to pass through based on their denier count. The higher the count, the less light that will be able to pass through. If you were to hold a piece of silk up against the sun, you would easily be able to see through it. However, if you were to do the same with a vinyl banner, it would block out all light, making it so you could not see through at all. This is important to consider with something like a pop up tent, where you will be mainly using it outdoors and will not want to have a lot of sunlight passing through the material.

What Are Some Common/Standard Denier Counts?

The denier count for fabrics, banners, and other materials can vary anywhere from less than 1 to 1,000+. Generally speaking, the thicker the fabric, the higher the denier count. Here’s a comparison chart to give you an idea of some common denier counts for materials you may be familiar with:

With so many different types of materials and applications relying on denier count as a measure of thickness and durability, it’s important to consider a material similar to the one you’re using when determining what count is best for you.  Generally speaking, microfiber materials like silk makeup anything that is 1d or less. Light fabrics such as down jackets and thin tents will be around 10-20d. General outerwear, such as t-shirts, sweatshirts, & khakis will range from 40-80d. Heavy-duty fabrics, such as flags, pop up tent canopies, backpacks, vinyl banners & more can range anywhere from 100-1,000d.

All of our signs are crafted for impressive durability; if you’re looking for a banner and are having trouble choosing one that would fit your needs, check out our vinyl banners, mesh banners, or fabric banners to learn more.  

Have any other questions about signs? Give us a call at 888-222-4929 or shoot us an email at support@signs.com

Signage 101 – What Is Denier?