Background
This project was developed as a Cyberpunk 2077–inspired wall banner, designed to bring the visual language of Night City into fans’ personal spaces. The product combines thick felt, screen-printed graphics, and a Velcro panel to create a functional piece of merchandise for decorating a gaming setup or personal den.
Challenge
The first challenge was achieving the right weight balance. The banner was made from three separate felt panels in black, yellow, and cyan, each with a different shape and size. Because the panels had different weights, even a small imbalance could cause the finished banner to tilt when hung.
The second challenge was the printing alignment. Each panel had different graphics and printing positions, and the graphics needed to remain visible and properly aligned after the three pieces were stitched together. Even small stitching tolerances could affect the final result, so the printing positions had to be carefully considered in advance.
The third challenge was the rough texture of the felt itself. The uneven surface made detailed printing difficult, especially for small text. Large graphics were easier to print because their larger areas could cover the underlying texture, while smaller text could easily become distorted or lose definition.
What I did
To solve the weight balance issue, I calculated the weight of each individual panel and adjusted the material distribution accordingly. By selectively adding or reducing material in different areas, I was able to achieve a balanced structure so the finished banner would hang vertically without tilting.
For the printing alignment, I created multiple prototypes to test the relationship between the printing positions and the stitching process. By studying stitching tolerances and potential overlaps, I identified the safer printing areas before moving into final sampling. This allowed me to validate the details early while keeping development and sampling costs under control.
To improve the printing quality on the rough felt surface, I developed a pre-treatment process. I applied a thin adhesive base layer to the printing areas first, creating a smoother and more even surface before printing. This was particularly important for the small text, while the same treatment was also applied to the larger graphics to achieve a more consistent finish.
Outcome
The final banner achieved a stable, balanced hanging position while maintaining the intended layered design and detailed graphics. The improved printing process also ensured that both large graphics and small text remained clear despite the rough felt surface.
The product performed very well commercially and sold out quickly, demonstrating strong demand from fans.
