DIGITAL FLATTENING SERVICES
3D SURFACE TO 2D PATTERN GENERATION
THE PROBLEM
Slow Manual Fitting: Traditional pattern making (upholstery,
marine covers, PPF) via trial-and-error takes days/weeks,
requiring manual draping and cutting “by eye”.
Material Waste: Manual cutting causes high scrap rates of
costly, luxury materials (genuine leather, advanced PPF).
Paint Damage Risk: Trimming PPF with knives directly on the
vehicle’s bodywork risks scratching the paint.
Elasticity Issues: Different fabrics stretch differently; flat
templates fail to predict wrinkles, seam tears, or distortions.
THE SOLUTION
Modern fabric-flattening software automates production
through a 4-step digital engineering process:
Step 1 (3D Scan/CAD): Importing a CAD model or 3D scan (e.g.,
seat, hull, Bimini). The software cleans the mesh and segments
it into assembly pieces.
Step 2 (Digital Ironing): The algorithm flattens 3D shapes into
2D templates, using color-coded maps to instantly flag high-
tension or sag areas.
Step 3 (Material Matching): Selecting a fabric from the built-in
library (leather, film, canvas). The system calculates and
neutralizes stresses to <1% based on real-world textile behavior.
Step 4 (Automated Output): Flat patterns (with pre-calculated
PPF edge wraps) are cataloged and ready for direct export to
CNC plotters or subcontractors.
TECHNICAL SIDEBAR
Application: Upholstery, PPF, vehicle wraps, covers, Bimini tops,
composites.
Industries: Automotive, Marine, Custom Projects, Premium Furniture,
Aerospace.
The Process: 3D Scan ➛ Mesh Segmentation ➛ Material Selection ➛
Stress Reduction (<1%) ➛ Digital 2D Patterns.
Key Advantage: Shorter lead times, zero material waste, instant
product digitization.
CUSTOMER BENEFITS
Speed & Automation: Multiplies pattern-making speed; creates a
reusable, digital template catalog.
Maximum Savings: Eliminates costly material waste on failed
manual attempts through precise computer nesting.
Flexible Outsourcing: Enables instant, error-free digital sharing of
production-ready patterns with external sewing/upholstery shops.
Flawless Fit: Reducing stress to <1% guarantees wrinkle-free
upholstery and perfectly straight seams from the first attempt.
Paintwork Safety: Pre-cut PPF kits apply like stickers, completely
eliminating knives on the car’s paint.
Versatility: Ideal for custom, multi-material, made-to-order
projects, which is critical in the demanding marine/yacht industry.
YOUR DIGITAL ENGINEERING PARTNER IN PATTERN GENERATION
We transform complex 3D surfaces into production-ready 2D templates for CNC
plotters and external subcontractors.