by Cassandra Balentine
Laser cutting solutions give print providers the capability to finish a variety of digitally printed fabric applications, from soft signage to apparel and even décor.
Above: Matik offers a range of SEI Laser solutions designed for cutting fabrics for various applications.
This is in response to changing market demands in an increasingly digital industry. “Businesses expect faster processing speeds, automation features, and consistent edge quality to meet increased order quantities without sacrificing precision,” shares Corey Kelly, marketing manager, Trotec Laser.
Laser technology has become an industry standard for soft signage applications. “Unlike flatbed systems, which can struggle with stretchable materials, laser cutters offer greater versatility and precision,” comments Randi Kerkaert, product manager, Summa. “Additionally, the laser’s ability to seal fabric edges simplifies the sewing process. Compared to traditional knife-based systems, which often require monthly or even weekly blade replacements, lasers offer longer operational life and lower maintenance needs.”
Changing Demands
The market is demanding higher cutting speeds and improved quality, especially with the rise of digitally printed textiles for short- and medium-run lengths across a range of verticals, including retail, residential, and signage.
“There’s interest in on demand garment customization from monograms and patches to full-cut pattern personalization. This trend expands laser cutting into athleisure, team uniforms, dancewear, and promotional gear—especially when paired with direct-to-garment printing or embroidery,” shares Kelly.
Steven Leibin, president, Matik, Inc., says laser cutters can offer fast, on-the-fly cutting from a printed roll; sealed edges for better quality; as well as higher overall throughput.
Beatrice Drury, communications manager, Zund America, Inc., sees manufacturers turn to digital cutting solutions for greater efficiency and precision. “This is true both for laser- and blade-based cutting systems, although the latter still offers much greater flexibility, which is precisely where modularity comes into play. The ability to easily switch from one type of cutting technology to another helps overcome the inherent limitations of single-purpose laser systems in terms of material compatibility, edge quality, slower throughput, emissions, and safety concerns.”
Necessary Features
Key features for fabric laser cutting include automated material handling, edge-sealing capabilities, and high-precision optics. “Over time, these functions have been enhanced with faster processing speeds, improved safety systems, and smarter material recognition,” offers Kerkaert.
As is the case with all types of digital cutting/finishing, Drury sees workflow automation as a must. “From tension-free material advancing to efficient, automated nesting and precise vision registration that reliably matches cut to print, automation reduces manual involvement, which means greater output quality and consistency, productivity, and ultimately, profitability.”
Kelly agrees, adding that print-and-cut camera systems are a necessity for digitally printed fabrics. “The ability to size, scale, and skew your cut files to match any deviations in print is a game changer for print companies.”
Automation in the Future
The past few years experienced major strides in automation and intelligent workflow integration, especially when it comes to textile applications.
“This is true for all system components, with smarter, more adaptive material handling; faster and more precise registration mark capture; advanced nesting algorithms; integrated, automatic file retrieval; and automated/robotic picking/sorting and off loading,” suggests Drury.
Kelly concurs, noting that automation in laser cutting for fabric is being adopted across garment manufacturing sites as well as technical textile industries. The reasoning behind this adoption is the fact that “print-to-cut systems enable continuous, high-precision cutting and support growing demand for customization and speed.”
Automation is often driven by advanced software tools.
For example, all of Summa’s digital cutting systems—including roll cutters, flatbeds, and laser cutters—are powered by the company’s proprietary GoProduce workflow automation software. “A standout feature is VisionTrace, which enables on-the-fly creation of cut files. This eliminates production bottlenecks by removing the need for preprepared cut files. The system automatically recognizes the shape to be cut and intelligently avoids mistakenly cutting white lettering or printed elements on the fabric,” explains Kerkaert.
Trotec’s Ruby software is a powerful, all-in-one platform that streamlines the laser workflow from design to production. With an intuitive interface, it allows users to create, edit, and manage jobs directly within the software—no need for external design programs. Features like the job queue, materials database, and direct-to-laser functionality help boost productivity, while the open API integration supports automation and custom workflows for businesses of all sizes.
“With improved registration technology, seamless Ruby software integration, and support for high-mix, short-run production, Trotec’s print-and-cut camera systems have become faster, more precise, and easier to use,” explains Kelly.
All software offered for running Zünd cutting systems can be tailored to specific applications and production needs. For graphics applications, regardless of application and processing methods, Zünd Cut Center (ZCC) V.4 makes everything from file preparation to production automation more intuitive, efficient, and reliable, with options for automatic data import in almost any format, job queues, and data exchange with ERP/RIP and other systems. From the touchscreen to the integrated material base and step-by-step guidance through setup, ZCC is geared towards user-friendly, efficient, error-free operation.
As with most technologies, artificial intelligence (AI) plays an increasing role in the future of automated finishing.
“Automation—and in a broad sense AI—is already playing a role in many different aspects of digital cutting processes. It is most evident in camera registration and automatic adjustments of cut paths, in smart nesting and pattern recognition, cut job and workflow optimization, projection-guided or robotic picking/sorting, and other advanced production workflows,” states Drury.
Kelly sees AI improving pattern recognition and optimizing nesting layouts to reduce waste. “Trotec’s Ruby software already incorporates smart features like nesting, which efficiently arranges designs to minimize waste. As AI continues to evolve, it will further streamline workflows and reduce manual input, paving the way for smarter, faster production.”
Automated Sewing
In addition to cutting, sewing is an essential part of the finishing process for multiple textile applications. The task of sewing is becoming easier and less labor intensive through automation, easing bottlenecks due to manual processes and making efficient laser cutting even more valuable to users.
Many of the processes used by large format print service providers (PSPs) are automated from design through print to cutting. Computers provide the controls necessary to end up with a cut-to-shape print. “However, if that print is a textile and must be sewn to complete a finished product, there is another labor intensive department with sewing personnel moving the textile under a stationary sewing needle. Much manual dexterity and movement is necessary to finish the sewn pieces, and as we know skilled labor is in very short supply,” shares Steve Aranoff, business development manager, Fastsewn dba Mikkelsen Innovation ApS.
However, he explains Fastsewn’s Moving Cavity Technology is a system that looks much like a flatbed cutter, but with the ability to have a sewing bobbin under the textile being sewn while the needle is on the traverse—just like any cutting tool, automated sewing allows for domestic production without the need to find and train staff. “Today, most PSPs are unable to profitably grow their sewing capabilities due to lack of such staff. With Fastsewn, anyone who can operate a cutter handles the sewing simultaneously,” shares Aranoff.
The Fastsewn family of systems provides a fully automated capability to sew and laser cut from up to two rolls of textiles. “This system unrolls and sews keder strips before laser cutting for silicone edge graphics, including the ability to do this in any shape for which an aluminum frame can be built. Two-sided graphics can be easily registered with an optional underside vision registration system,” adds Aranoff.
Tara Giffin Lamb, president, Global Imaging Inc., sees automated sewing becoming increasingly imperative in today’s evolving workforce due to several converging factors.
“The high speed of modern fabric printers demands equally efficient post-processing to keep up with production flow. At the same time, the rising cost of labor and growing demand for fabric graphics put pressure on manufacturers to optimize efficiency and reduce operational costs. Compounding these challenges is a shortage of skilled labor and employee turnover, making automation a critical solution for maintaining consistency, quality, and productivity,” notes Lamb.
The Miller Weldmaster Digitran, distributed by Global Imaging, sews at up to 20 meters per minute, and the conveyer measures 10×2.5 feet. The conveyor is synchronized with the sewing head for smooth material transport. It also integrates tension-free keder feeding as well as automatic, programmable backstitch and thread cutting.
Finishing Automation
When it comes to finishing digitally printed graphics on textiles, laser-based cutting and automated sewing are key to quality and profitability. The technology is in need more than ever due to labor shortages. Textile-focused PSPs should consider implementing.
Jul2025, Digital Output Magazine
