The Washington Post is reporting that the American flag, an enduring symbol in a polarized era, undergoes a carefully choreographed manufacturing process. It said that at Valley Forge Flag Co., located outside Charleston, S.C., workers transform red, white and blue thread into the globally recognized symbol.
The process begins with thread, where fabric is washed, inspected, and checked for flaws, requiring UV-resistant fibers to prevent fading. Structural components like the heavy-duty polyester canvas header are added for durability. The stars are embroidered first using Schiffli machines on blue rectangles, known as the canton, at Embroidery Solutions. These are then meticulously inspected by hand for imperfections.
The article explains that strips of red and white nylon are then sewn together with the blue field of embroidered stars. The final steps focus on endurance, with edges folded and stitched to prevent fraying, and the fly end reinforced. Metal grommets are pressed into place at Lane Manufacturing. Workers treat the finished flags with respect, adhering to traditions once they pass inspection. The Post noted that Valley Forge Flag Co., tracing its roots to 1882, has historically seen demand surge during moments of national unity and reckoning, such as after Pearl Harbor, 9/11, and during both world wars.