How-Powder-Puffs-Are-MadeHow-Powder-Puffs-Are-Made

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How Powder Puffs Are Made

Powder Puffs are one of the biggest items used in Hollywood. Not very many people know much about their manufacturing much less the raw materials that go into the making of a good powder puff.

Puffs come in all shapes and sizes and are filled with a variety of materials and fabrics. Not until recently our research and development assisted in developing a powder puff that was "state of the art" and definitely, "outside the box".

The concept and usage of a powder puff never changed until Hollywood demanded changes based on the "grease" makeups that were used in the early 1900's. Up until that time puffs were large pieces of fur that one "puffed" on to the face, deleting shine and adding a small amount of color (lighter) to the face. The insides of the fur puff were made from fine down feathers, cotton, and fleece. Early customers using loose powders, which were sold in large wide-mouth containers would purchase a large furry powder puff that went into its own specific container. The customer would remove the puff from the "Puff Box" and use it to apply powder from the powder box. Puff boxes were made form paper, glass and metals. In 1844 velour was invented in Lyon, France. The word "Velour" is derived from the French term for velvet. However, there is no accurate date where velour was first used with the powder puff. Velour is made from cotton, wool, or spun rayon. Most professional powder puffs (used by professionals) are cotton. With the innovations of synthetic fibers and materials the outside "fur ball" was replaced by velour (velvet type of brushed cotton).

Technically, it was not until later years that research was done determining the use of synthetic fibers. When used with loose powder synthetic have superior intake abilities. So many synthetic fibers were utilized it was necessary to determine the right fiber length as well as the correct distance from fiber to fiber, each with different fiber widths and pile lengths. This was compared to cotton (velour) puffs that were the standard in the professional industry. No one knows why they were the standard by the way ñ they were the only ones used and many professional makeup companies and distributors still used the standard cotton puff to this day.

In the past few years, micro-fibers have been used and have been evaluated and studied for use as the intake fiber (material used for the exterior fabric) of the powder puff.

DMK Cosmetics has been working with one of the largest powder puff companies and materials manufacturers in the world to determine the right combination of fabric, filler and size to enable the most intake of powder and the best deliverance of powder on the face. We have concluded our research and are proud to introduce the DMK Pro-Puff. The DMK Pro puff has a series of steps vital to the manufacturing of a powder puff that has superior intake ability as well as excellent delivery ability to the cosmetic ñ without picking up the cosmetic.

The DMK-Pro Puff is a peach colored micro fiber made exclusively for DMK Cosmetics. After we receive the fabric we send the fabric to an adhesive fabric where a mesh fabric is attached to the backside of the material with a special flexible adhesive that will not dilute of dissolve in water.

Figure 1 - Special manufactured peach microfiber is ordered and cut to the correct size.Figure 1 - Special manufactured peach microfiber is ordered and cut to the correct size. Figure 2 - Special mesh is attached tot he back of the fabric adding strength and durability. Mesh is adhered by special adhesive not soluble in water.Figure 2 - Special mesh is attached tot he back of the fabric adding strength and durability. Mesh is adhered by special adhesive not soluble in water.

A lightweight soft density polyfoam sponge is used for the core of the puff. This is durable, offers excellent fill, will not bunch or fold, and withstands water and dries quickly if washed. Our puffs are 93mm wide and 6mm in height. We use a 4mm sponge as the core of our puff.

The micro-fiber is die cut into 95 mm circles in a special fabric die cutting press. It takes 2 circles of microfiber to make one Pro-Puff.

Figure 3 - Die cut arrangement of microfiber fabric and 95 mm diameter circles used to make the outside of the DMKC Pro-Puff.Figure 3 - Die cut arrangement of microfiber fabric and 95 mm diameter circles used to make the outside of the DMKC Pro-Puff. Figure 4 - Filler sponges being cut in same pattern in 95mm circles.Figure 4 - Filler sponges being cut in same pattern in 95mm circles.

The two round microfiber circles are sewn together (inside out) leaving a 2 - 3 mm space for reversing the Pro-Puff in the finishing process.

Figure 5 - Inside out and sewed with a durable nylon thread showing a 2 to 3 mm insertion hold for reversing the puff.Figure 5 - Inside out and sewed with a durable nylon thread showing a 2 to 3 mm insertion hold for reversing the puff.

Next the sponge is set on the puff and the puff is turned inside out, through the 2 - 3 mm hole from the stitching.

Figure 6 - The foam on top of the stitched puff ready for turning inside out.Figure 6 - The foam on top of the stitched puff ready for turning inside out.

The core foam pad is placed on the center of the puff and turned inside out. This process exposes the outside of the Pro-Puff for the first time. It also shows the gap from where the puff hem was machine sewed. This gap is hand sewn in order to hide stitching with a strong nylon thread.

Figure 7 - P-DMK Pro-Puff turned inside out showing the hem gap.Figure 7 - P-DMK Pro-Puff turned inside out showing the hem gap.

The finished puff is shaken off to remove small bits of fabric that might stick to the puff during the manufacturing process DMK-Pro puffs used a special machine, like a clothes drier, but rather than blowing warm air, our machine extract air while circulating the puffs.

The puffs are packaged in clear polybag and ready for distribution.

DMK Pro-Puffs are the newest addition to the "outside the box" products at DMK Cosmetics. These superior quality puffs will hold loose powder (intake), and deliver a smooth, thin layer to any cosmetic. They are easily washable and are very durable. The microfiber fabric is soft yet will deliver the right amount of powder without soaking deep into the puff, or spillage from the puff from over loading.

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