Business challenge 

Manufacturers in every soft goods industry need to deliver innovative solutions with increasing consumer demand for customized product.  At the same time, these companies are constantly evaluating ways to maintain or even reduce sky-rocketing production costs, and to transition to localized and sustainable manufacturing.  

To address these challenges, most manufacturers of textiles products or fashions are actively weighing the value of adopting new technologies such as digital patterning and 3D bonding.   The impact that these tools are having on labor costs and production times is readily apparent. The true question manufacturers face today is in determining when and how to implement these business-critical solutions.  

Digital Patterning – reduce pattern making efforts

3D CAD and digital patterning integrate the entire design process, eliminating manual manufacturing preparation steps and increasing design flexibility.  The new workflow process is streamlined from start to finish:

1. Start with the design concept and develop the design into a 3D model.

2. Add the customization features that your clients are demanding.

3. Flatten the 3D model into 2D pattern pieces in minutes.

4. Complete the finishing tasks.

   1. Label the pieces for assembly

   2. Add custom graphic motifs

   3. Nest the patterns and optimize the material usage

5. Finish the job by sending the final pattern(s) to the automated cutting equipment.
   

The digital patterning process presents a small change in efforts while delivering significant cost and time savings.  And the opportunities for process improvement don’t stop there. 3D bonding, which replaces wasteful manual sewing methods while enhancing the ability to ensure fit and comfort, provides another huge business improvement opportunity.

3D Bonding – eliminate sewing and assembly labor

The development and introduction of 3D Bonding grew from a need in the apparel, foot wear, furniture and automotive industries to:

• radically simplify and optimize production processes, skills requirements, and labor

• reduce distribution costs by allowing companies to produce close to the consumer.  

With 3D bonding, soft goods manufacturers start with the pattern pieces created by the digital patterning tools in ExactFlat.

Next the pattern pieces are placed in molds similar to those used for an injection molded part or a product made from composite materials.   The difference is that now designers can use this process with fabric and leathers.

The last step is to inject a liquid adhesive material into the mold.  This forms the firm three-dimensional skeleton for the part as well as eliminates the sewing and assembly steps.

Key advantages

Simpler Product Construction

3D Bonding is a superior solution to current sewing manufacturing processes because it is proven to reduce construction steps.  In a recent prototype project for a global footwear manufacturer, the automated and highly reliable 3D bonding process was used to reduce 70 assembly preparation and sewing operations to about 20.

Cheaper, Reduce labor and material costs

Obviously manual labor is drastically reduced, in some cases by as much as 75%.  Adopting a 3D Bonding process also means using less material since the material for seam allowance overlapping is eliminated.  This has a tremendous impact, especially on high quality and expensive materials such as leather products.

Better Solution Overall

Simply stated, 3D bonding is just better than sewing:

• Better comfort:  No internal seam materials to cause irritation.

• Better Performance: The union between parts is completely waterproof. If the pattern materials are also waterproof, the finished product is self-sealing.

• Better wear and tear: Molding helps eliminate strain on fabric, which ensures the appearance of the product for longer.

• Better Design: 3D Bonding allows for a broader variety of design options that can not be duplicated with sewing assembly methods.

Learn More

Digital Patterning and 3D Bonding can change the profitability of your business.  That is a fact. The only question is what’s holding you back. To learn more, please join us for a free webinar hosted by ExactFlat and Simplicity Works to review the process and tools and to gain a better understanding of how to get started.  Or simply contact us at sales@exactflat.com .   

Digital Patterning and 3D Bonding webinar - February 19, 2019

ExactFlat is partnering with Simplicity Works to host a series of webinars. These events showcase ways to utilize 3D design, Digital patterning and 3D Bonding to improve productivity in any industry.   Click on the images to learn more and to sign up for the event.

About the Partner - Simplicity Works

At Simplicity Works we envision a future with a more respectful and sustainable relationship between factories, companies, consumers, textile workers and the planet. With our revolutionary technology, we are making this future happen today. 3D Bonding enables manufacturers to deliver locally produce products that are more durable, more comfortable, and more cost effective. Simplicity Works - Simply Better