In short, the flocking process involves applying short monofilament fibres, usually nylon or rayon, directly on to a substrate that has been previously coated with an adhesive. The diameter of the individual flock strand is only a few thousandths of a centimetre, and ranges in length from 0.25 - 5 mm. Adhesives that capture the fibres must have the same flexibility and resistance to wear as the substrate. The process uses special equipment that electrically charges the flock particles causing them to stand-up. The fibres are then propelled and anchored into the adhesive at right angles to the substrate. The application is both durable and permanent. Flock can be applied to glass, metal, plastic, paper or textiles. Flock design applications are also found on many items such as garments, greeting cards, trophies, promotional items, toys and book covers.

Flock can be made from natural or synthetic materials such as cotton, rayon, nylon and polyester. There are two types of flock - milled and cut. Milled flock is produced from cotton or synthetic textile waste material. Because of the manufacturing process, milled flock is not uniform in length, and can vary from fine (0~ - 0.5 mm) to coarse (0.4 - 1.1 mm). Cut flock is produced only from monofilament synthetic materials. The cutting process produces a very uniform length of flock. Lengths can be obtained from 0.3 - 5.0 mm and 1.7-22 dtex in diameter. (One dtex is the measurement of a fibre that weigh; one gram per 10,000 meters of length.)

The fineness of the flock, length of fibres and adhesive coating density determine the softness of the flocking. It should be noted however, that fine or short flock is difficult to work with, since i has a tendency to ball-up during processing. Milled cotton flock has the advantage of being the lowest in cost and the softest, but has the least abrasion and wear resistance. Rayon is a little bit better on wear resistance and nylon is the best. For cut flock, rayon is the least expensive with the least wear resistance. Cut nylon is the best grade of flock and produces a good feel, but is also the most expensive. Cut polyester is basically used for industrial applications such as automobile window seals, glove compartments, and roofing. Besides cutting or milling, flock manufacturing includes several other steps. After cutting, the flock is cleaned of oils that accumulated during processing. It is vat dyed to any number of colours, and then chemically treated to enable the fibres to accept an electrical charge. Since the fibres are all dielectric, a certain amount of conductivity must be present for electrostatic flocking process to occur. When the process is complete the fibres are spin dried and then oven dried to a specific moisture content. Note that flocking fibres are never totally dried, since moisture content adds to their conductivity. Finally, the flock is packaged in moisture proof bags that maintain proper humidity.

The same patch produced with flock (top left) and embroidery (top right.). Underneath are close-ups of both patches.
Flocking is a value-added alternative method for achieving an unusual look. It costs only slightly more than screenprinting, yet is certainly less expensive than embroidery.