Digital Patterning

Welcome

This site is for industry professionals interested in faster, more profitable pattern making with digital patterning.

Scan to Pattern to Piece - Accelerating Furniture Manufacturing

Scan to Pattern to Piece - Accelerating Furniture Manufacturing

Furniture Manufacturers already know that they can no longer remain competitive by making a-thousand-samples-of-one-design or relying on legacy manual processes.  Process automation is critical in order to thrive in the reality of today's lower production volumes, and custom product demands. 

Making the transition to digital solutions like 3D CAD and ExactFlat digital patterning helps companies implement a mass-customization approach.  This enables shorter delivery time and sustainable profit on any given production order.

Automated Digital Design and Production Workflows

In today's environment it is relatively easy to realize dramatic productivity improvements by simply linking together readily available and tested technologies.    In the case of automating furniture design and fabrication, a few key process automation solutions should be considered.

Create the 3D model from scratch or via 3D scanning

Most process enhancements in this market benefit greatly from the use of 3D digital design models.  3D models communicate the design intent to all team members and can be utilized directly in all downstream tasks including frame construction, pattern making, and automated production and assembly documentation.

Recent advances in 3D CAD usability as well as access to pre-trained users has contributed to wider adoption of these tools in the furniture market segment. 

 3D Scanners provide a simple way to convert physical furniture pieces into 3D digital models. Click on the image to see the process in action.

3D Scanners provide a simple way to convert physical furniture pieces into 3D digital models. Click on the image to see the process in action.

For manufacturers who want to leverage existing production templates or prototypes  as inspiration for new designs, 3D scanning has also proven to be a viable approach for digital design creation.  These tools capture the geometric details of the physical piece converting them to 3D models that are edited or enhanced in the 3D CAD system.

Convert the 3D Model to 2D Patterns

The process to convert the 3D model has be simplified significantly with the introduction of digital patterning tools like ExactFlat.  A process that previously took hours or days can now be done in minutes by using the software to directly convert the 3D model into 2D pattern pieces.   In addition, the use of strain and sag reports automatically created as part of the flattening process provides the added advantage of reducing follow on fit testing and prototyping.   

                  Start with a 3D design 

                 Start with a 3D design 

 Flatten the 3D design into 2D pattern pieces

Flatten the 3D design into 2D pattern pieces

Once the 3D model is created or imported using 3D scanning, ExactFlat digital patterning software is used to convert 3D models into 2D pattern pieces in minutes.

Optimize the Material usage

Depending on the size of the job, material waste can often erase any profit.  Nesting software is another area where a nominal investment in software results in significant cost and time savings.  The newest generation of nesting tools allow manufacturers to combine pattern pieces (marker sets) from multiple projects into a single nested production job. 

Increase Productivity Now

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Start saving time and money on your next product today.  Click on the image below to schedule a one-on-one demonstration customized for your business.

You can also make plans to meet with Mark Jewell CTO of ExactFlat (Mark.Jewell@exactflat.com )if you or someone on your team is headed to the Home Furnishings Manufacturing Solutions Expo (Greenville SC, USA.  July 18-19, 2018)

 If you use patterns in your production process and you want to increase the profit on every part, then you need to learn more about ExactFlat Digital Patterning

If you use patterns in your production process and you want to increase the profit on every part, then you need to learn more about ExactFlat Digital Patterning

3D Bonding Eliminates Sewing

3D Bonding Eliminates Sewing

What's the Business Case for the Transition to Digital? - Part I

What's the Business Case for the Transition to Digital? - Part I