Production Process III
Cutting
In the cutting department, the prepared fabric surface is turned into the specific basis for each individual garment. This is where it is determined how precisely a model can later be assembled. The fabric is laid out in layers, carefully aligned and checked to size before computer-controlled cutting takes place. Digital pattern data specifies exactly where each contour runs and how the pieces are optimally positioned on the fabric. The goal is 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 further processing.
"The knife has to be replaced after 2 working days."
CAD
All patterns are digitally constructed and managed. Fits, size ranges, seam lines and design details are created on screen and combined into optimized cutting layouts. This digital planning enables efficient use of the fabric and ensures that cuts are precisely prepared. 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 exactly matches the defined specifications. Digital pattern development therefore forms the basis for consistent quality in further processing.
Cutting Tables
In the cutting department, the fabric is laid out in several layers without wrinkles or distortion. Depending on the material and quality, the layers can be stacked up to 150 fabric layers high. The layers are then not fixed mechanically, but stabilized using vacuum technology. This keeps the material positioned exactly and allows it to be cut precisely. Computer-controlled cutting systems work with high accuracy and ensure that all parts are identical in size. Only when the cutting is exact can seams be assembled cleanly and fits be maintained reliably. Offcuts are also systematically processed further. Some are used internally and turned into smaller items such as hats or cleaning cloths. Another portion is passed on to external companies that continue to use the material. This keeps the material flow traceable and ensures that the raw materials used continue to be utilized sensibly.
Preparation Department
In the preparation department, the cut pieces are brought together and prepared for further processing. The individual cut parts are bundled and assembled into production-ready units. Each bundle receives a production card containing all relevant information for the subsequent work steps. The production card includes, among other things, the item number produced from these layers, the color number, the size of the item and the number of pieces in the respective layers. This information ensures that all further processing steps can be clearly assigned. The bundles are then passed on in an organized manner to sewing production. 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 precisely cut and sorted, the next processing step begins.
In garment production, the prepared cut pieces are assembled and processed into a wearable garment. Here, fit, workmanship and seam construction come together, and individual fabric pieces become a finished product.
