Seamless Garment Technology,Application
And Benefits
Nikhil Bhosale1,Bajirao
Jadhav1,vishnu pareek1,Shrikant Eklahare sir2
1 Department of Fashion And Clothing Technology, D.K.T.E Society’s ,Final Year,
Maharashtra
State Board of Technical Education, Ichalkaranji-416115,India.
2Department of Textile , Faculty
of Finishing , D.K.T.E Society’s, Ichalkaranji-416115,India.
Abstract:
No
sewing, no seams, no stitches. That's seamless. A specific knitting technology,
using specialized circular looms to develop garments that adapt perfectly to
the body, making people forget that they are actually wearing them. By
eliminating the fabric cutting and sewing process, there is an optimization of
the production process making seamless production a lot faster than conventional.
There is also a fewer product failures since most errors, since most of the
garment failures are due to seam failure, which translated in better quality
pieces.
By eliminating the
cutting and sewing processes, complete garment knitting provides a variety of advantages
in knitting production such as savings in cost and time, higher productivity,
quick response production and other advantages.
Keywords: Knitting, tubular, seamless, complete garment, Application.
1. Introduction:
Seamless garment is a kind of one-time forming
clothes produced by seamless knitting machine. In the existing production
system the cutting and sewing process is mostly labor oriented. The sewing
process may create needle hole on the sewn product and also the stress created
at the seam portion. Process which creates the human error, Seamless garment
technology is advancement in apparel industry which eliminates the fabric
laying, cutting and sewing process. In addition to that seamless garment gives
more comfort. Circular knitting machines were used for making seamless garment
in earlier days. Taking the leap from knitter to designer is one that many
knitters find quite daunting, but it needn’t be. This class will explore a
variety of different seamless garment construction possibilities (raglan, circular yoke, saddle
shoulders, set in sleeves) before moving onto sizing and grading, knitting the
sample/prototype, copyright and ethics, resources and support, pattern writing,
pattern testing, finding inspiration, yarn selection and selling your
patterns. Participants will begin the grading and sizing process for their
own raglan sleeved garment. Please bring along yarn and appropriate needles. If
you have an idea before the class that is fabulous, but don’t feel that you
have to. While the class will use child garment design as the example, it will
also address how this can be applied to adult garment design as well.
2. Seamless garment technology how it
work?
· The process for making seamless garments
requires the use of cutting-edge circular knitting machines, mostly made in
Italy, which complete whole garments based on preprogrammed computer commands
that allow for different stitching patterns.
· The product is a finished or semi-finished
garment with no side seams.
· Seamless technology has transformed the overall
worldwide production process, helping apparel firms react quicker to trends
because the garments do not have to be cut and sewn. This technology can directly
produce finished products, and lessens traditional process of the production.
This leads to saving of production costs up to 40 percent compared to the customary
knit-ting.
· Biggest challenge is to educate the consumer
about the range of benefits that seamless garments have to offer.
3. 1Seamless knitting machines:
1) Santoni is now known as the world leader in seamless machine
manufacturing.
- They
have produced the seamless warp knitting machine with the model of SDW 8.
It is a double needle bar Raschel machine contains 8 guide bars with a
working width of 44 inches.
- This
machine can form 2 seamless garments side by side in a chain formation,
which can be separated later by cutting.
2)
Santoni has recently introduced the SM4 TL2 machine, which shapes the knitted
tube and will eliminate the cutting process.
3)
The new machine produced from KARL MAYER, called "Seamless Smart" is
designated as 'DJ' series.
- The
very first machine in this series is DJ 4/2, developed by Nippon Mayer
Ltd.
- The
working width of this machine is 42", can operate at a rate of 1,000 stitches
/minute.
4)
The Shima Seiki company invented the Whole Garment® machine and introduced
the commercial complete garment knitting (SWG-V machine) in 1995 at ITMA
(International Textile Machinery Association).
4. Benefits of Seamless Garment Technology:
4.1 Design Possibilities:
· With our focus on innovation and quality, producers
are constantly developing new seamless styles to meet customer's demand.
· Development of new fibres and knitting
adaptation are continually evolving. New advancements coming from fibre
producers and yarn spinners will continue to provide innovation from the supplier
side.
· Based on the structure of the knit, the
patterns and construction of the garment cannot be matched with any other
non-seamless garment and the ability to combine textures and levels of
compression opens up endless possibilities for coloured patterns, jacquards, ribbing
and detailing.
· There are endless design possibilities
with seamless technology, with the variety of different stitches that can be
achieved within a single garment, for example a jersey knit can be placed
side-by side with a mesh knit, a rib knit, a jacquard knit. This is impossible
to do with any other type of knitting process.
· The features of seamless technology benefit the
retail store and ultimately the end consumer, who will notice a difference once
they try on a seamless garment. Once the consumer wears it, it offers a
high-repeat purchase ratio. Consumers are only beginning to understand the
benefits of seamless technology.
· Because of the versatile nature of seamless technology,
there are infinite opportunities in the market," both locally and internationally.
The seamless concept can be applied to underwear, swimwear, control-wear, leisurewear,
sleepwear, ready to wear and active wear.
4.2 Pricing:
- Unlike a regular knitting
machine, which produces yards of the same pattern that need to be cut and
sewn, the seamless machines produce individual garments from yarn that is
fed into the machine-Retails for about 10-15 percent more, because of the
specialized equipment involved and the high demand for such limited
availability of machinery.
- This benefit is worthy of a
price increase, meaning certain part of knitting/apparel category such as
intimate, active wear market can be justified due to above listed benefits
since some of its features cannot be accomplished in conventional circular
knitting or cut & sew method.
4.3 Fit:
- The garments are precisely
fitted to the body, producing a smother, clean look.
- Seamless garments conform
smoothly to your individual shape and produce fewer lines under clothes to
allow for a more streamline silhouette.
- The softness of seamless
knitwear combined with the use of antimicrobial and hydrophilic yarns
create the best features for an activewear garment.
4.4 Comfort:
- Wearers love seamless garments
because they are forgiving, non restrictive and are not binding. The lack
of seams provides for improved comfort as the body moves.
- With an increasing demand by
consumers for more comfortable and better-looking clothing. Seams tend to
pucker up, and tags chafe against the skin. Seamless garments feature
knitted in shaping to eliminate bulky elastics and provide enhanced
comfort.
- The main seamless products are
underwear, outerwear, activewear, shapewear and swimwear, all of which are
highly elastic, fine to very fine fabric, made of micro-fibers, required
to be very extensible and soft; therefore adding to comfort.
4.5 Quality and Durability:
- Besides offering higher comfort
and better fit to consumers by eliminating seams, the innovative technique
creates entire garments with minimal intervention of cutting and sewing
processes leadingto substantial savings in cost and time, higher productivity,
quick response, and just in-time production.
- Seamless garments have no
waistband failures, no waistband or side seam failures and are more durable
due to the high proportion of manufactured fibres such as nylon
- The broad technical application
of selective engagement and disengagement can be adopted sensibly to
produce a ready to use customized garment thereby reducing wastage of
cloth.
- With traditional production
methods, fabric is the starting point for most garments. The fabric is
dyed, patterns are cut, and then the pieces are sewn together. If printing
or embroidery is part of the design, these are additional steps that take
place later in the production process. But with seamless production, there
is no fabric. One Italian machine can make the entire product in just
minutes; and the machine automatically knits components like waistbands
and hems.
- Seamless garments take 30
percent to 40 percent less time to make than a cut-and-sew version
minimizes the traditional labour intensive step of cutting and sewing.
5. Application of seamless garments:
5.1 Protective textiles:
- THE Seamless filament-knit
gloves and apparel are available on the market. They are
lightweight, flexible and comfortable for workers in the electronics,
food-handling, paint, plastics and other high precision business sectors
which require high levels of safety in addition to contaminant-free cleanliness.
5.2 Ready to wear:
Santoni says those who
desire instant fashion enjoy the versatility and creativity that is in constant
evolution.“Smart fibres or intelligent garments are suited to any occasion.
Sophisticated garments capture glamour in motion. Seamless apparel offers
both fashion and function for those who want to create their own benchmark for
style. Garments produced through seamless technology create comfort
during those times when the wearer wants to relax and unwind. Products
offer freedom of movement for one's own schedule at one's own pace,” the
company says.
5.3 Sports textiles:
Seamless apparel construction focuses on
supporting muscles. The development of advanced second-skin textiles has
led to renewed interest in seamless garment construction. A diverse range
of products such as gloves, hats, and socks are some of the more obvious
applications. Swimwear also offers exceptional fit through the use of
elastic and quick-drying yarns.
5.4 Sports bra features heart sensing technology:
A new seamless heart-sensing controlling sports
bra is offered on the market. It is designed to give greater support
during high impact sports. Textile electrodes are knitted into the bra
and stretch and move with the wearer, maintaining contact with the skin and
sensing the heart's electrical pulses. Dr.Rita Paradiso, Ph.D., Research
Director of Smartex, Italy, explains:"Conductivity is the main property
being exploited and for our applications, knitted technology is the right
one, because we need different domains within the fabric structure
with different types of yarns. We have to decide in which places we need
to put the conductive yarns and where background yarns are used, because the
values of resistance change depending on their position. Of course, we
need a garment which fits like a ‘second skin’ because the bio-electrode
is in direct contact with the skin.”
5.5 Medical textiles:
According to Santoni the onset of seamless
technology in the medical arena has led to advantages for those times when the
body needs it most. With the incorporation of high performance fibres and
additional sensors or electronics, and the unique combination of fibres which
are designed for comfort, the required functions of the garment are
achieved.
6. Conclusion:
By this review paper we conclude of some of the
important points as following:
This seam less technology can directly produce
nearly finished product. Seamless garments are in vogue and the demand for
such garments particularly under wears is increasing. Presently these seamless
garments available in the market are knitted one. Woven garments are not
available. Seamless garment made of tubular material are well known. Lot of
innovations are being carried out in to this technology, very soon this will
change the transformation in apparel business
Acknowledgement:
To
make an a research paper,The people
helped with the if a, Shrikant Eklahare sir, Staff, family and friends. Acknowledge a heart felt,
thank you, for their paper.
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ONLINE ARTICLE : http://www.fibre2fashion.com/industry-article/49/4854/seamless-garment-technology1.asp
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