Working on the bicorn again. I ordered the gold foil print for the hat badge from multiple vendors. All turned down the job. As noted above, one very plausible method is screen printing but I wanted to try this new toner foil. This stuff will not stick unless placed on something that is itself, sticky. There are two main types of plastic backed transfer foil. One has no sticky backing and is called toner sensitive. It really is just adhesive free. You have to put it on something that can become an adhesive which is why toner works when reheated. The second type is referred to as heat foil. It already has a layer of heat sensitive adhesive and therefore transfers directly to many surfaces.
The trick is getting gold foil but only on the image or text you intend. The heat foil would transfer over the whole area and would need to be precut to shape first. This means it acts like vinyl stickers that are cut but cannot do fine detail. The toner foil will stick to toner but also to heat transfer adhesives.
The normal process is: First step, print the image on a laser printer.
Second step, place the foil on the toner image and reheat. Then peel the plastic off and the foil will leave behind only the areas that came in contact with toner. This is as far as most foil users go. Now the negative image still remains on the foil.
Third step, some foil users have then used the negative to decorate either a fully toner covered black paper or a special white paper made for this. It has an adhesive layer on the face.
I figured that I could use this process to do what several online vendors said could not be done, using this method to transfer a high def foil image to leather without having a metal die of the image and the expensive, die heat press.
I printed the negative of my image on a laser printer. This is an important step. This allows you to remove all the foil you do not want, leaving only the foil image that you do want. This is the step the online vendors failed to grasp:
Then I laid the toner sensitive foil on it. Shiny side up. I placed these in a protective paperboard ironing sleeve and hard pressed on max heat. Very hard pressed.
Then waited for it to cool and peeled it away. I attempted to use a laminator but it has no pressure and failed continuously. I read that a Minc brand laminator works perfectly. I used a regular clothing iron.
I then placed tshirt inkjet transfer sheet paper on my leather. Placed it in another paper sleeve and ironed the clear adhesive onto the leather.
I waited for it to cool entirely. Peeling too early will pull up the adhesive. I then placed my now positive gold foil image on top of the leather and adhesive prepped surface. Placed these back in the paper sleeve and re-ironed. Waited for it to cool, peeled the plastic and I had a finely detailed, gold foil image on leather. I used a black alcohol marker to cover any extra gold that trasferred.
Final step was cutting out the round image from the leather.