Production Process III
Cutting
In the cutting department, the prepared fabric is turned into the specific basis for each individual garment. This is where the precision required for the later assembly of a style is determined. The fabric is laid out in layers, carefully aligned and checked for dimensions before being cut by computer-controlled systems. Digital cutting data specifies exactly where each contour runs and how the individual pieces are positioned in the fabric as efficiently as possible. The aim is to achieve a high level of dimensional accuracy while using the material efficiently. Only when the cutting is precise can seams be joined cleanly and fits be maintained reliably. The cutting department therefore forms the technical basis for consistent quality in the subsequent processing stages.
"The blade has to be replaced after two working days."
CAD
All patterns are digitally constructed and managed. Fits, size ranges, seam lines and construction details are created on screen and combined into optimised marker layouts. This digital planning enables efficient use of the fabric and ensures that the cut pieces are prepared precisely. Changes to patterns can be implemented quickly and transferred reproducibly to additional sizes. CAD combines design requirements with technical feasibility and ensures that every cut piece corresponds exactly to the defined specifications. Digital pattern development therefore forms the basis for consistent quality in the subsequent processing stages.
Cutting Tables
In the cutting department, the fabric is laid out in several layers without creases or distortion. Depending on the material and quality, the stack can contain up to 150 layers of fabric. The layers are then stabilised using vacuum technology rather than being mechanically fixed. This keeps the material precisely positioned and allows it to be cut accurately. Computer-controlled cutting systems operate with a high level of precision and ensure that all parts have identical dimensions. Only when the cutting is exact can seams be assembled cleanly and fits be maintained reliably. Cutting waste is also processed systematically. Some of it is used internally and made into smaller items such as hats or cleaning cloths. Another portion is passed on to external companies that process the material further. This keeps the material flow traceable and allows the materials used to be processed further.
Preparation Department
In the preparation department, the cut pieces are brought together and prepared for further processing. The individual cut components are bundled and assembled into production-ready units. Each bundle receives a production card containing all relevant information for the subsequent work stages. The production card includes, among other details, the article number being produced from these layers, the colour number, the size of the article and the number of pieces in the respective layers. This information ensures that all subsequent processing stages can be clearly assigned. The bundles are then passed on in an organised manner to the sewing department. The preparation department ensures that materials, information and workflows are clearly structured and that production can continue in a traceable and efficient way.
Once the individual pieces have been cut precisely and sorted, the next processing stage begins.
In garment production, the prepared cut pieces are assembled and made into a wearable garment. This is where fit, workmanship and seam construction come together, turning individual fabric pieces into a finished product.
