Case study
Cinema screen
THE PROJECT
An international manufacturer of high-end cinema screens asked us to develop a solution to automate the cutting and sewing of their products.
Screens are made from an expensive PVC-coated material that enhances the quality of the projected images. The patterns are rectangular with straight or curved edges and small holes that are used to mount the screen on an aluminum structure. After the cut, Velcro straps are sewn to the back of the fabric
THE PROCESS
For this project we combined two of our machines – the SM-375-TA cutting plotter and the SM-100-CA linear sewing station – into a single production line with 2 individual work stations. The first part pulls the fabric off the roll and cuts the patterns according to a CAD drawing. The fabric is then forwarded to a second station. Fabric transportation is made easy with the flying carpet principle created by an air cushion underneath the fabric. A single operator can easily forward even extra-large pieces from the cutting to the sewing station.
The sewing station then consists of a high-performance sewing head that runs along the side of the machine. To allow the operator to monitor and guide the fabric and Velcro strap during the sewing operations, while at the same time guaranteeing his work comfort and safety, we created a platform with chair that travels together with the sewing head on which the operator can safely sit while producing.
Creation of high-end products.
We installed two high-power welding heads on the and right side of the tool bridge to fold the fabric into a pocket and insert the core that is used to attach the fabric to the awning structure.
As the machine works at exceptionally high speeds (up to 15 mt/min), we integrated an accumulator before the cross-cutting station so that the machine does not have to slow down or come to a full stop, instead continuing the welding process during the cut.
With the new cutting and sewing machine our customer is now able to produce cinema screens in a continuous cycle. While the sewing station attaches the Velcro straps to the back of the product, the cutting station automatically spreads and cuts the fabric, so that there are no dead times in the process.
