Here’s How:

Context
A leading motorcycle seat manufacturer approached ExactFlat with the goal of improving their pattern-making process. They were at the design phase, experimenting with various pattern options for their seats but were struggling with the limitations of manual methods. Their primary aim was to speed up production, maintain accuracy, and assess different design options for costing and appearance.

Problem
The client’s key challenges were:

• Slow and inconsistent pattern creation: Manual methods were time-consuming and often led to inaccuracies.

• Inefficient experimentation with design options: Testing new configurations was labor-intensive, causing delays and driving up costs.

• Difficulty in evaluating costs: The manual process made it challenging to quickly assess different design options and their cost implications.

• Risk of losing manual pattern makers: They needed to modernize their workflow by transitioning to digital methods for improved speed and accuracy.

Solution
ExactFlat recommended using a 3D digital scanner to capture the geometry of the motorcycle seat, transforming the physical model into a digital 3D representation. The digital file was then processed by:

1. Smoothing and aligning edges for precision.

2. Removing unwanted geometry like holes and imperfections.

3. Smoothing surfaces to ensure accuracy.

With the 3D CAD model finalized, various split lines, representing different pattern design options for both aesthetic review and costing purposes. This enabled the client to quickly compare multiple design configurations and accurately assess their financial implications. The final patterns were converted from 3D to 2D and features like seam allowances and notches were applied. 

Results
The client was able to produce perfectly fitting patterns in less time and at a lower cost, making their operations more efficient and competitive. Using a 3D scanner and ExactFlat:

• 3-5x faster pattern creation: Pattern development time reduced from days to hours.

• Greater accuracy: The patterns were precise to within 0.1 mm, minimizing errors.

• Instant costing assessments: The client could evaluate different design options and their costs in minutes, significantly speeding up decision-making.

• Reduced costs: Eliminating manual steps and reducing errors led to a 100% reduction in overall project costs.

Discussion
ExactFlat streamlined the client’s pattern-making process by:

• It eliminates the unnecessary steps of manual pattern making.

• It maintains accuracy without cutting corners. 

• It allows for rapid experimentation of different designs without having to re-create patterns from scratch. 

• Lastly, ExactFlat is Fully compatible with 3-D scanners and we have made it easy to learn and use both.

Conclusion
The combination of ExactFlat and 3D scanning enabled the client to accelerate pattern-making while improving accuracy and cutting costs. By digitizing their workflow, they were able to complete 3 to 5 times more work in the same amount of time.  If you would like to learn more about why ExactFlat Scan-to-Pattern is faster, easier, and more accurate, give us a call. We’ll show you how.