Simulation of 301 lockstitch at different stitch densities for the prediction of sewing thread consumption

Sewing threads are a critical component in garment manufacturing, and accurate prediction of their consumption is essential for efficiency and cost reduction. This study employs CATIA software to simulate 3D modeling of a 301 lockstitch under varying stitch densities and thread counts. The simulation determines the required sewing thread length for producing this stitch type, incorporating physical properties of sewing threads and fabric layer thickness.

Three stitch densities (3, 4 and 5 stitches per centimeter, SPC) were modeled, with fabric thickness measured using a digital thickness gauge to enhance accuracy compared to conventional computational approaches.

Validation was performed by comparing simulation outputs with experimental values obtained through the unraveling technique and with results from established geometrical based models methods.

The findings demonstrated that the CATIA based simulation achieved high accuracy (2.62 % error) in predicting sewing thread consumption, outperforming conventional geometric approaches. Furthermore, this study highlights the influence of stitch density and fabric thickness on thread usage and establishes a reliable computational framework for industrial applications. Unlike earlier studies that relied primarily on mathematical or geometrical approximations, the novelty of this research is the use of advanced CAD simulation (CATIA V5R21) combined with experimentally measured fabric thickness to predict sewing thread consumption, providing a more accurate and versatile framework for garment manufacturing.