News-Releases Index | Gerber Technology
20th Century Fox Selects Gerber to Produce Replica Costumes for The Greatest Showman Premiering in December (10/24/17)
In every aspect of the fashion world, digitalization is driving the demand to bring new styles to
market faster. This is also true for the world of film and costume creation. Costume replicas are
costly and, in the past, they were all done by hand. But recently Gerber Technology combined forces
with Global Garment Engineering and 20th Century Fox to replicate costumes worn by Hugh
Jackman, Zac Efron, Michelle Williams, Rebecca Ferguson and Zendaya in the upcoming film The
Greatest Showman (in theaters around the world starting Christmas Day). By leveraging Gerber’s
integrated digital solutions, they can now be done in a fraction of the time and at a much lower cost.
The challenge 20th Century Fox presented was to produce 50 sets of replicas of beautiful and
complicated costumes in a very short time frame to support the film’s release. The product experts
at Gerber, working closely with their partner Pat Trautman at Global Garment Engineering, accepted
the challenge and leveraged Gerber’s industry leading products and team expertise to digitally
deconstruct each costume garment without having to take them apart. The job started by digitizing
each garment on the Gerber SilhouetteTM table, where pattern files were instantaneously created in
AccuMark® – the industry-leading pattern design, grading, marker making and production planning
software. The patterns were simultaneously passed into AccuMark 3D, where they were draped on
avatars to validate pattern pieces and review virtual samples. The digital sampling process allowed
the team to ensure the patterns would accurately and precisely be sewn together to create perfect
“Precision as we digitized the original costumes into the patterns was key to achieve the speed and
quality we needed to accurately replicate these beautiful garments in such a short time frame.”
stated Mary McFadden, executive director of CAD at Gerber Technology.
Prior to project kickoff, photographs, technical sketches, measurements, component details and
assembly instructions were compiled within YuniquePLM® to ensure planning, management and
tracking of each essential step was executed properly and timelines were met.
After the patterns were validated in AccuMark 3D, data was passed to AccuNest™ to create markers
ensuring the optimum yield was achieved from the beautiful and expensive fabrics needed to
produce the costumes. Over 22 diverse fabrics were spread and cut. “By using AccuNest, we were
able to achieve a 3-6% improvement on fabric yield which was a substantial cost savings for the
project” said Mary McFadden. A cut ticket was then generated for each of the garments to pass data
from technical design through to production. The barcode on the cut ticket transfers all the fabric
and marker data essential to efficiently spread and cut each costume.
In the cut room at Gerber’s headquarters in Tolland, Connecticut, product experts loaded the fabric,
scanned the cut ticket on the GERBERspreader™ XLs125 where the spread details were automatically
transferred without manual re-entry of any of the information. After monitoring the spread, the
material was passed on to be cut using the Gerber Paragon® HX. At the Gerber Paragon, the cut
ticket was scanned again to pull up the marker for each garment. After carefully managing the
process and labeling the bundles of cut parts, they were packed and shipped to New York for
Pat Trautman and her team from Global Garment Engineering brought their expertise and passion to
ensure every detail was handled on time and with a constant focus on ensuring the quality of the
replicas would match the designer’s vision for each of the original costumes.
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