Despite the fact that most apparel CAD and pre-press software applications are quite performant, the above mentioned process actually does not happens like this in most companies who produce digital printed sportswear. For the very simple reason that apparel CAD and pre-press applications do no interact and cannot cooperate to do the job.

In reality, most producers use an apparel CAD solution to design and cut the parts from white fabric. In  a totally separated process they prepare the graphics and print it to paper. Grading is done by manually scaling the graphics to match the altered dimensions of the patterns. Positioning the white pieces of fabric onto the printed paper is made purely by hand, involving high production costs.

For the first time, GeminiCAD introduces PDFtoPATTERD plugin for Pattern Desgner software. Producing custom-made sportswear with digital printing has never been easier. Graphics are imported in PDF format directly into the CAD application.

The content is placed on the pattern and automatically graded using the same technique as in normal apparel grading.  The PDFs will be embedded in the CAD file. Once this is done, the workflow will be a typical one for apparel production:  the CAD file containing the PDFs will arrive in Gemini Nest Expert, where it will be automatically nested at high efficiency, using Rotation and other nesting functions and restrictions. Once nesting is done, Gemini Nest Expert will export two files: one for the digital printer, the other for the cutter.  Both files incorporates logical elements which shall be used later by VisionCUT for automatic scanning and cutting the file.

The capability to handle PDFs and to apply apparel grading procedures, combined with the ability to nest patterns containing graphics into one large marker, translates into a total automatization of the process, all the way to the cutter.

PDF graphical content passes through Gemini Pattern Designer and Gemini Nest Expert undamaged, without any alteration of the quality or properties of the original files, and the result is a large format PDF with same quality level and color properties, which can be sent directly to the printer.

Preparing the jobs for producing digital printed sportswear requires several separate parts:

  • Design and grade the patterns following a classical apparel CAD workflow
  • Design the graphical content in a pre-press application
  • Merge the patterns shapes with graphics content for each individual size
  • Nest the parts in long markers with high efficiency
  • Print the parts in roll
  • Cut the parts