Patent ID: 8377246

Claim:
A process for producing a thermal appliqué having a multi-color multi-layer 3D appearance, comprising the steps of: printing a graphic design on one side of an upper textile layer by depositing ink in a plurality of areas; adhering a lower base layer beneath said upper textile layer, said lower base layer further comprising a solid color substrate; laser-etching said upper textile layer to provide a plurality of surface relief features corresponding to said plurality of ink areas, said etching step further comprising the substeps of, using a laser to etch said surface relief features using a first pattern of cross-hatching lines that do not penetrate said upper textile layer, using said laser to etch said surface relief features using a second pattern of cross-hatching lines periodically intersecting said first pattern of cross-hatching lines and penetrating said upper textile layer at each intersection to reveal the color of said lower base layer there through; and adhering a first thermal adhesive layer beneath said lower base layer, said first thermal adhesive layer having a first melting point.