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This article presents models for predicting thread consumption of lockstitch seam. Various fabric and sewing thread parameters like fabric thickness, number of plies and sewing thread diameter were found to be the control factors in thread consumption calculations. New equations were developed from real stitch images by creating realistic stitch models of lockstitch seam. Lockstitch was modeled using elliptical, racetrack and circular geometry. Elliptical and racetrack models were verified by stitching samples at different feed rates by comparing actual and predicted thread consumption. Scatter plots of both models were made to check the level of accuracy with actual values. The proposed model offers relatively less error% as compared to previous rectangular and elliptical models. Racetrack model came out as the most simpler, versatile and accurate model of thread consumption calculation of lockstitch. It was found that circular model is suitable for the samples stitched at equal stitch spacing and fabric assembly thickness.

Geometric model of lockstitch seam and prediction of thread consumption