SEAMLESS AND STITCHLESS TECHNOLOGY USED IN
APPAREL INDUSTRY
Author: Adrija Chakraborty
Guided by: Ms.Nilima R. Topno (Associate Professor, Nift Patna)
National Institute of Fashion Technology, Patna
1 ABSTRACT
The apparel industry is embracing innovation in adhesive technology to reduce fabric waste
and improve efficiency. Stitchless technology, like automated adhesive dispensing, offers
increased precision, profit margins, and productivity. This technology reduces chemicals,
water, and energy used in clothing production and reduces trash. Additionally, seamless
garment technology eliminates the need for stitches, seams, and sewing, resulting in quicker
and more effective manufacturing. This approach reduces the likelihood of product failures and
higher-quality items.
Stitchless and seamless garments offer comfort, durability, aesthetics, and performance
benefits. However, they also have potential disadvantages in design, production, and lifecycle.
To fully realize their potential, innovation, process optimization, and sustainable practices are
needed. The future of these garments is expected to be characterized by customization,
sustainability, and enhanced functionality.
KEYWORDS: Stitchless, seamless, productivity, manufacturing, comfort, durability,
aesthetics, and performance.
2 INTRODUCTION
Manufacturers in the apparel industry are focusing on innovation in adhesive technology to reduce
fabric waste and improve efficiency. Advancements in stitch-less technology, such as automated
adhesive dispensing, have led to increased precision, profit margins, and productivity. Stitch-less
technology is becoming more popular due to its high flexibility, strong bond, and resistance to
washing. As environmental awareness grows, businesses are taking more care in their
manufacturing procedures, leading to a positive opinion on stitch-less technology. This technology
reduces the amount of chemicals, water, and energy used in clothing production and the volume
of trash produced. There are several different types of stitch-less fabric joining techniques like
ultrasonic welding, laser bonding, and adhesive bonding. (Fernandoon, 2022)
Another amazing advancement in the fashion industry is seamless garment technology, which does
away with the need for stitches, seams, and sewing. With the use of specialized circular knitting
machines, this technique produces apparel that fits and molds to the body with unmatched comfort.
Production process optimization allows for the elimination of labor-intensive fabric cutting and
sewing procedures, which leads to quicker and more effective manufacturing. Moreover, as many
garment problems are connected to seam failures, seamless production lowers the possibility of
product failures while eventually producing higher-quality items. (RAO, 2022)
3 TECHNOLOGY USED FOR STITCHLESS GARMENT
3.1 ADHESIVE BONDING
At the joint interface, it employs a different substance that attaches to the substrate
mechanically or chemically. The glue can attach when a carrier (such as water or solvent)
evaporates or it can react chemically or thermally. The majority of woven and nonwoven
fabrics, whether synthetic or natural, are free of synthetic fibers. Additionally, it can be used to
attach clothing to non-textile embellishments like foil, glitter, etc. (ROHAN, 2024)
3.2 CONVENTIONAL THERMAL WELDING
The thermal process of welding necessitates melting fabric materials. It is also possible to apply
an additional heat-activated adhesive substance. The cloth is heated by coming into close
contact with a heated tool surface or hot air. Completely or partially synthetic (woven and non-
woven) textiles made of thermoplastic elements that, when fused together, are compatible both
chemically and physically. Since adhesive bonding and welding transfer stresses more
efficiently than other joining techniques, they are frequently used to combine items of clothing
that require a high seam strength, such as sportswear, shoes, and protective.
3.3 ADVANCED THERMAL WELDING
It is comparable to traditional thermal welding, with the exception that the cloth is heated
indirectly by coming into contact with a laser, electromagnetic field, or ultrasonic horn. It is
also possible to apply an additional heat-activated adhesive substance. Completely or partially
synthetic materials (often woven) made of thermoplastic pieces that, when fused together, are
compatible both chemically and physically.
3.4 HOT-AIR WELDING
Hot air is directed between the plies of the materials to be connected in hot-air welding
techniques in order to melt the substrate surface. The employment of a cold roller or another
instrument then facilitates the flow of the melt and the wetting of the fibers. Ultimately, the
melt cools by contact with the cold surface, forming a cohesive connection. The fabric itself
can be used as the hot-melt adhesive if the fabrics are thermoplastic. On the other hand, another
thermoplastic material (such as a film, coating, or powder) with a lower melting temperature
may be added to the joint area if the fabric has a high melting temperature.
3.5 FLAME LAMINATING EQUIPMENT
Another method of hot-air bonding that's mostly used to keep fabric and foam together is flame
lamination. A thin layer of molten polymer is created on the foam surface by passing a foam
sheet over an open flame. The assembly is then sent through a set of rollers to match with the
fabric. When the melted foam surface cools, it becomes sticky. The most common material for
flame lamination is PU foam.
4 TECHNOLOGY USED FOR SEAMLESS GARMENTS
Seamless garment production relies on state-of-the-art circular knitting machines, often
manufactured in Italy. These machines execute entire garment construction based on
preprogrammed computer commands, allowing for a range of stitching patterns.
The result is a fully finished or semi-finished garment that lacks side seams, enhancing both
comfort and aesthetics. Seamless technology has revolutionized global apparel production by
enabling faster response to fashion trends. Garments no longer require cutting and sewing,
streamlining the production process and reducing costs by up to 40 percent compared to
traditional knitting methods. (Nikhil Bhosale, 2013)
5 DIFFERENCE BETWEEN STITCHLESS AND SEAMLESS
GARMENTS
OBJECTIVES STITCHLESS GARMENTS SEAMLESS GARMENTS
What does it Seams are present in this kind of These types of garments contain
mean? garment and panels are generally no seams in larger places.
joined mechanically or chemically However, smaller components are
using substrate or by applying joined with the garment by the
external force. process of stitching.
Fabric Woven, and non-woven, fabrics are Knitting technology is used to
/Material used generally used. make a tubular structure that
eliminates seams from the
garment. Hence knitted material is
the base.
Period/ time It takes very little time to join the It might take some time to make
panels using this technology. stitches in smaller areas like
collars, pockets, etc. But the time
is less than normal stitching.
Technology ultrasonic welding, laser bonding, A circular knitting machine nails
used and adhesive bonding are used. the job.
6 EXAMPLES OF STITCHLESS AND SEAMLESS
GARMENTS
6.1 STITCHLESS NAVY PARKA
This study explores the possibility of new stitchless techniques replacing needle and thread
sewing as a technological route to the future of clothing manufacturing. The technological
advancements will improve human factors, lessen weight and bulk, and produce better-
performing clothing for our client, the US Navy.
The U.S. Navy conducted a 90-day field trial in Alaska with the prototype Stitchless Navy
Parka, which weighs 30% less than the current model and functions admirably. This was
made possible by research and development efforts. One of the Navy testers asked for an
endless supply of the clothing, demonstrating their extreme enthusiasm. (LLC, 2022)
TECHNOLOGY USED: HOT AIR WELDING
Figure 6-1: STITCHLESS NAVY PARKA (LLC, 2022)
6.2 NESATEX SEAMLESS DRESS
Nesatex makes beautiful seamless dresses in gauges 14 and 18 gauge. The elegant example
below in 75%/25% wool/nylon rib structure takes only 12 minutes to knit in gauge 14. The
company employs Santoni’s SMDJ technology in a range of different cylinder sizes in order to
offer a full range of dress sizes. (Textiles, 2012)
TECHNOLOGY USED: 3D KNITTING MACHINE
Figure 6-2 NESATEX SEAMLESS DRESS (Textiles, 2012)
6.3 GLUEJEANS
Gluejeans are apparel for would-be exhibitionists or people who like to be daring because there
are no stitches in the seams. The jeans are just held together with really strong glue. The raw
pieces of cut denim are connected with different coloured glue. In the close up picture, the bold
lines created by the glue adds to the individual look of these jeans and a change from the
traditional stitched seams.
The Dutch design duo, G+N, say Gluejeans was tested for two years to ensure durability.
Gluejeans is a limited addition line and hand made in The Netherlands. (TRENDHUNTER,
2008)
TECHNOLOGY USED: ADHESIVE BONDING
Figure 6-3 GLUEJEANS (SHEIN UK, 2021)
6.4 CALVIN KLEIN STITCHLESS QUILTED HOODED JACKET
Calvin Klein Menswear offers a premium selection of men’s styles from tailored suits to luxury
sportswear.This jacket is crafted with recycled materials.The outer material is made with 55%
certified recycled polyester. The filling is made with 100% REPREVE recycled polyester from
plastic bottles. REPREVE recycled polyester is made from certified recycled plastic bottles.
recycled polyester blend, stitchless quilting, texture contrast fabric at neckline, hood and
sleeves, regular fit, stand-up collar, zip fastening, slit pockets at the waist, technical zippers,
REPREVE midweight recycled polyester insulation, Calvin Klein rubberized logo badge on
the sleeve, extended sizes available. (CK, 2022)
TECHNOLOGY USED: ADVANCED THERMAL WELDING(LASER)
Figure 6-4: CALVIN KLEIN STITCHLESS QUILTED HOODED JACKET (CK, 2023)
6.5 STITCHLESS JACKET
Ultimate must have clothing for the wardrobe of an urban fashionista with holistic lifestyle,
made from the best quality Bluesign and Oeko-tex certified functional materials, which are
sourced and manufactured in Europe. Individually constructed clothing by using bonding and
taping technique developed by LAENE SCANDINAVIA has not been sewed or stitched.
Clever, lightweight and easy care gear without irritating seams or labels. Ergonomic cut and
stretchy breathable fabrics allow unrestricted movement. (STITCHLESS, 2021)
TECHNOLOGY USED: ADVANCED THERMAL WELDING(LAZER CUTTING)
Figure 6-5 STITCHLESS JACKET (STITCHLESS, 2021)
6.6 BRUBECK’S SEAMLESS INTIMATE WEAR
Filati’ own brand Brubeck also makes high tech seamless cotton based underwear with
polypropylene on the inside. The microfibre polypropylene transports moisture making the
product both comfortable to wear and easy to iron.
TECHNOLOGY USED: 3D KNITTING MACHINE
Figure 6-6 BRUBECK’S SEAMLESS INTIMATE WEAR
6.7 WACOAL SEAMLESS BRASSIERE
BRAND: WACOAL
TECHNOLOGY USED : MOULDING
Figure 6-7WACOAL SEAMLESS BRASSIERE
6.8 SEAMLESS BODYSUIT
BRAND: H & M
TECHNOLOGY USED: 3D KNITTING MACHINE
Figure 6-8 SEAMLESS BODYSUIT (H&M, 2023)
6.9 STITCHLESS SPORTS BRASSIERE
Bostik’s global range of high-performance, hot melt polyurethane adhesives make it easy to
address stitchless clothing application needs while also reducing raw material costs. Compared
to alternative options, such as adhesive films, they provide:Good bond strength and ideal
washing resistance to improve end-use performance elasticity to increase consumer appealLow
jetting and hot-press temperature requirements via automated jet, spray and roll dispensing to
enhance operations
TECHNOLOGY USED: ADHESIVE BONDING
Figure 6-9 STITCHLESS SPORTS BRASSIERE (BOSTIK, 2022)
6.10 SEAMLESS TWISTED-FRONT PENCIL DRESS
TECHNOLOGY USED: 3D KNITTING MACHINE
Figure 6-10 SEAMLESS TWISTED-FRONT PENCIL DRESS
6.11 SEAMLESS TUBE TANK TOP
BRAND: H & M
TECHNOLOGY USED: 3D KNITTING MACHINE
Figure 6-11 SEAMLESS TUBE TANK TOP (H&M, 2023)
6.12 ARROW STITCHLESS SHIRT
Arrow launched a luxury shirt collection, Superluxe – The Stitchless Shirt. While the
traditional method is to join fabric panels via sewing to make a shirt, adhesive material
[THERMOPLASTIC] to join fabric components has been used in making this shirt. The shirt
has been manufactured by ARVIND . It is claimed that the technology will solve the issue of
puckering at the armhole, side seam, and shoulder seams of shirts. (ZEENEWS, 2013)
TECHNOLOGY USED: HOT AIR WELDING
Figure 6-12 ARROW STITCHLESS SHIRT (NNNOW, 2013)
6.13 SEAMLESS FORMAL SKIRT
TECHNOLOGY USED: 3D KNITTING MACHINE
Figure 6-13 SEAMLESS FORMAL SKIRT
6.14 SEAMLESS FORMAL T-SHIRT
TECHNOLOGY USED: 3D KNITTING MACHINE
Figure 6-14 SEAMLESS FORMAL T-SHIRT
6.15 WOMEN’S SEAMLESS SWIMSUIT
TECHNOLOGY USED: 3D KNITTING MACHINE
Figure 6-15 WOMEN’S SEAMLESS SWIMSUIT
6.16 WOMEN’S SEAMLESS BIKINI
NALLAs are manufactured from a single piece of seamless Lycra that can be used as the top
or bottom of a swimsuit. With a simple twist, knot or accessory, our patented design allows
you to create unlimited styles and looks without compromising functionality or comfort.
TECHNOLOGY USED: LAZER CUTTING
Figure 6-16 WOMEN’S SEAMLESS BIKINI
6.17 SPEEDO MEN'S FASTSKIN SWIMSUIT (INSPIRED FROM SHARK SKIN)
Speedo’s Fastskin line of high-tech, high-performance swimsuits were inspired by the skin of
a shark–shark skin’s sandpaper-like texture is thought to reduce drag, hence its usefulness in
swimming gear. However, a Harvard ichthyologist's study revealed that Fastskin is "nothing
like shark skin at all," and that its surface characteristics do not even slightly lessen drag.
Figure 6-17 SPEEDO MEN'S FASTSKIN SWIMSUIT
6.18 SPRAY BASED FABRIC
Manel Torres Coperni Spring-Summer 23 creation ‘Fabrican’ is a liquid spray based fabric.
His idea was to elevate the coarse cords of the silly strings into a finer fabric that could be
dispersed through a mistIn a 2013 Ted Talk, Torres described how this spray-on cloth
becomes a solid, stretchable substance that resembles suede when it comes into touch with
air. The liquid fabric is composed of a suspension of liquid polymers, which are big
molecules bound together, additives, binders such as natural latex, cross-linked natural and
synthetic fibers, and a fast-evaporating solvent such as acetone, according to the patents
awarded to the company.
The fibers can be polyester, polypropylene, cotton, linen, or wool.
Figure 6-18 SPRAY BASED FABRIC
7 ADVANTAGES OF STITCHLESS AND SEAMLESS
GARMENTS
Stitchless and seamless garments offer several advantages over traditional stitched garments:
• Enhanced Comfort: Seamless construction eliminates seams and stitches that can
cause irritation or chafing against the skin. This results in a smoother and more
comfortable fit, especially for form-fitting garments like activewear or undergarments.
• Improved Durability: Stitchless construction eliminates the weak points created by
seams and stitching, which are often the first areas to wear out or fray in traditional
garments. This can lead to increased durability and longevity of the garment.
• Sleek Aesthetic: Seamless construction creates a clean and sleek aesthetic, free from
the visible lines and bulkiness associated with stitched seams. This minimalist look is
often preferred for modern and high-fashion designs.
• Better Fit and Silhouette: Seamless garments can be engineered to conform more
closely to the body's natural contours, providing a better fit and silhouette. This is
especially beneficial for activewear, shapewear, and performance apparel where
freedom of movement and a streamlined appearance are important.
• Reduced Weight and Bulk: Without the need for seams and excess fabric to
accommodate stitching, seamless garments tend to be lighter in weight and less bulky.
This can improve comfort, mobility, and breathability, particularly in apparel designed
for sports and outdoor activities.
• Customization Potential: Seamless construction techniques, such as 3D knitting or
printing, offer greater flexibility for customization and personalization. Garments can
be tailored to individual body measurements and preferences without the constraints of
traditional pattern-making and stitching.
• Reduced Production Time and Waste: Seamless garment production can be more
efficient than traditional stitching methods, resulting in shorter production times and
less material waste. This can lead to cost savings for manufacturers and a reduced
environmental footprint.
• Functional Integration: Seamless construction allows for the integration of functional
elements directly into the fabric, such as compression zones, ventilation panels, or
moisture-wicking properties. This can enhance the performance and functionality of the
garment without compromising aesthetics.
8 DISADVANTAGES OF STITCHLESS AND SEAMLESS
GARMENTS
While stitchless and seamless garments offer numerous advantages, they also come with
some potential disadvantages:
• Limited Design Flexibility: Seamless construction techniques may impose
limitations on design options compared to traditional stitched garments. Complex
designs with intricate details or contrasting panels may be more challenging to
achieve seamlessly.
• Higher Production Costs: The equipment and technology required for seamless
garment production can be more expensive upfront compared to traditional stitching
methods. Additionally, specialized training may be needed for workers to operate
these machines effectively, adding to production costs.
• Quality Control Challenges: Achieving consistent quality in seamless garment
production can be more challenging due to the complexity of the manufacturing
process. Variations in materials, tension, or machine settings may result in defects
or inconsistencies in the finished garments.
• Repair Difficulty: In the event of damage or wear, seamless garments may be more
challenging to repair compared to traditional stitched garments. Stitchless
construction techniques often involve bonding or fusion methods that may not be
easily undone or repaired without compromising the garment's integrity.
• Limited Material Compatibility: Some materials may not lend themselves well
to seamless construction techniques, particularly those that are stiff or difficult to
manipulate without stitching. This can restrict the choice of materials available for
seamless garments, limiting design options or performance characteristics.
• Longer Development Time: Designing and prototyping seamless garments may
require more time and iteration compared to traditional methods, especially when
incorporating innovative materials or technologies. This can delay time-to-market
and increase development costs for new product lines.
• Scalability Challenges: While seamless production can be efficient for small-scale
or custom orders, scaling up production to meet larger demand volumes may pose
challenges. Manufacturing capacity, equipment maintenance, and workforce
training may need to be addressed to accommodate increased production levels.
• Environmental Concerns: While seamless construction can reduce material waste
during production, it may also involve the use of specialized materials or processes
that have environmental impacts. Additionally, the disposal of seamless garments
at the end of their lifecycle may be more challenging due to the integration of
different materials or components.
9 FUTURE OF SEAMLESS AND STITCHLESS
The future of stitchless and seamless garments is likely to see significant advancements in both
design and production techniques. Here are some potential trends and developments:
• Advanced Materials: As textile technology advances, new, flexible, and long-lasting
materials will be created, enabling seamless construction that eliminates the need for
stitching. Advanced synthetic fibers, biofabricated textiles, and intelligent materials
that adapt to the wearer's demands and the surroundings are a few examples of these
materials.
• 3D Printing: Technologies for 3D printing are already being investigated for the
creation of seamless clothing. These technologies have the potential to completely
change how clothing is created and designed as they grow more sophisticated and
accessible. The constraints of conventional stitching methods can be overcome using
3D printing, enabling the creation of elaborate and intricate designs.
• Personalization and Customization: The fabrication of seamless and stitchless
garments is ideally suited for personalization and customization. Customers may be
able to alter clothing to fit their tastes, body types, and style preferences thanks to
developments in digital design and production techniques.
• Production Efficiency: The manufacturing process may be streamlined by using
seamless garment production, which might lower waste and labor expenses related to
conventional stitching techniques. Scaling up production without sacrificing
consistency and excellent quality may be greatly aided by automation and robotics.
• Functional Apparel: Seamless construction allows functional aspects to be woven
right into the fabric, such as moisture-wicking properties, compression zones, or even
electrical components for wearable technology applications. This could lead to the
production of apparel with enhanced comfort and performance alongside a fashionable
look.
• Sustainability: Because stitchless and seamless garment manufacture can minimize
material waste and energy usage, it may be more ecologically friendly than previous
processes. These methods might grow more popular as attempts to reduce
environmental effect increase and sustainability becomes a more crucial factor in the
fashion business.
10 CONCLUSION
Stitchless and seamless garments offer a combination of comfort, durability, aesthetics, and
performance benefits that appeal to both consumers and manufacturers alike. As technology
continues to advance, we can expect further innovations in seamless construction techniques
and materials, leading to even more advantages in the future.While stitchless and seamless
garments offer many benefits, including improved comfort, durability, and aesthetics, it's
essential to consider these potential disadvantages in the design, production, and lifecycle of
these products. Mitigating these challenges through innovation, process optimization, and
sustainable practices will be key to realizing the full potential of seamless garment
technology.The future of stitchless and seamless garments is likely to be characterized by
innovation, customization, sustainability, and enhanced functionality, driven by advancements
in materials science, manufacturing technologies, and consumer demand for more versatile and
comfortable clothing options.
11 REFERENCES
I. CK. (2022). Retrieved from CK: https://ro.calvinklein.com/recycled-puffer-jacket-
k10k108291beh
II. CK. (2023). CK. Retrieved from https://images.app.goo.gl/XB15Xn6UyimhZHp98
III. Fernandoon, L. (2022, APRIL 23). Bondville. Retrieved from
https://bondville.lk/blog/advantages-of-the-stitch-free-apparel-technologies/
IV. LLC, P. (2022). Propel. LLC. Retrieved from
https://images.app.goo.gl/ZjRwhnBrBURBPj1y7
V. Nikhil Bhosale, B. J. (2013, AUGUST). Seamless Garment Technology, Application
and Benefits. Retrieved from FIBRE2FASHION:
https://www.fibre2fashion.com/industry-article/7047/seamless-garment-technology
VI. RAO, P. (2022, JUNE 18). INDIA CSR. Retrieved from INDIA CSR:
https://indiacsr.in/putting-together-stitchless-fabrics-through-innovation-and-
technology/
VII. ROHAN. (2024, January January 8). KNOWING FABRIC. Retrieved from
https://knowingfabric.com/what-is-bonded-clothing-and-how-does-it-benefit-
fabrics/#:~:text=Adhesive%20Bonding%3A%20This%20method%20involves%20ap
plying%20a%20bonding,to%20create%20a%20strong%20bond%20between%20the
%20materials.
VIII. SHEIN UK. (2021). Retrieved from
https://images.app.goo.gl/qiuoJZSsUbfiqJTu6
IX. STITCHLESS. (2021). Retrieved from
https://www.notjustalabel.com/collection/laene123/stitchless
X. Textiles, I. i. (2012, DECEMBER 6TH). Retrieved from
https://www.innovationintextiles.com/merino-gains-ground-in-seamless-sportswear/
XI. TRENDHUNTER. (2008). Retrieved from
https://www.trendhunter.com/trends/stitchless-jeans-glue-jeans
