We all know this, but what does it really take to get it right the first time, every time?  Today, I say we look at Patterns.

Some of the case patterns, waiting for their turn on the tables.

After the design process has taken it’s course, and the product has been finalized, its time to begin the production process.  The first step, is creating the pattern, where each case is broken down into its individual pieces, like the image at the left of this paragraph.

Using the hard patterns we have, each piece is meticulously drawn and marked.

From here, the process begins to get a little more complicated.  As you all  know, each of our cases are made from a variety of materials, each there for one purpose or feature.  While some materials are cut by machine (usually Vinyl, the famous Slip-Dot that adorn most of our cases, and other plastic or delicate fabrics), the majority are cut by hand.

Each piece is carefully place on the material, and traced on to long sheets of material in order to reduce as much scrap as possible.  All of these pieces don’t all belong to just one product, multiple pieces from different cases will be placed on a single sheet of fabric.

 

Once the lines are drawn, let the cutting begin!

When cutting large amounts of fabric we use a kind of table saw, that has a thin and incredibly sharp blade, as well as wheels to make make each cut as smooth and straight as possible while reducing the chance of fraying edges.  This process can be done with multiple sheets of fabric, in order to greatly reduce the time needed to prepare multiple cases for sewing.

Finally, the the pieces are laid out and marked.  These marks will provide the sewing teams a visual reference for where handles, logos, pockets, etc all are located in order to ensure consistency throughout the process for all product lines.

After these pieces have been checked, they are off to the sewing floor.

This is the first of many steps it takes to create the high quality cases that we are known for.  See you next time!