This job came to me from the US Navy at Dam Neck Navy Base in Virginia Beach Virginia. Because there is dye-sublimation involved in this job the physical size became a bit of a challenge for my equipment so there was some outsourcing required to make this one happen. I should give credit to Conde for printing the large graphics, Halmarc Solid Surface Products for the beautiful seam work and to Norva Plastics for engraving the text on their large format Kern laser engraver.
The first picture (A) was a quick sample to check out my very old heat press. The press hasn't been used in awhile so I felt it necessary to make sure there were no problems with any of the heater coils. Got my 320 degrees after a 60 minute warmup and after 20 minutes in the press the sample logo looked pretty good.
The job was too large for my heat press so I decided to do the graphics one at a time. The 4 by 5 foot job was cut into 3 pieces of Corian with the edges prepped for glueing back together before they were placed in the press. Picture (B) shows the narrow top piece in the press to dye-sublimate the logo. In the foreground you can see the paper graphic for the flag on the center piece which was 29.75" by 60".
Picture (C) shows the top piece out of the press and the large center piece cooking in the press. Both pieces were placed in the press on top of a custom cut piece of plywood that provided support for the Corian end to end while it was hot and during the cool-down period.
Picture (D) is another shot of the top piece in the press.
Picture (E) is a bit fuzzy but you can see how the piece was clamped to the plywood backer. The blue tape provides the match-marks for the edges.