Sewing is the process of fabric joining by the uses of needle and thread. This is the dominant process in garment assembly, still the best way of achieving strength and flexibility in the seam as well as flexibility of manufacturing method. It is a universal and widely used method of fabric joining.
The main purpose of sewing is to produce a satisfactory seam.
Seam:
A line along which two or more fabrics are joined usually near the edges by sewing or alternative methods.
The properties that seams have to achieve can be stated quite simply at an introductory level, but the factors involved in achieving those properties are complex and interrelated.
The objective of sewing is the construction of seams that combine the required standards of appearance and performance with an appropriate level of economy in production.
Seam Appearance
Seam Performance
Seam Appearance:
Good appearance in a seam normally means smooth fabric joins with no missed or uneven stitches and no damage to the material being sewn. Alternatively it may mean regular gathering to create a style feature or a varying but controlled amount of ease to ensure a good fit to the body. In other cases, fabric may be stretched deliberately to achieve an effect but the amount should still be predetermined and controlled. With the wide variety of fibre types and fabric constructions available, good seam appearance during manufacturing demands varying techniques. Once it has been achieved, it must be maintained throughout the designed lifetime of the garment, despite the additional problems that arise during wearing, washing and dry cleaning processes.
Seam Performance
Performance of seams means the achievement of strength, elasticity, durability, security and comfort, and the maintenance of any specialized fabric properties such as waterproofing or flameproofing.
Strength:
Seams must be as strong as the fabric, in directions both parallel and at right angles to the seam.
Seam strength should be lower or equal to the fabric strength. If the seam strength is higher than the fabric strength then the fabric may damage due to unexpected force encountered in the use of the sewn item.
Elasticity:
They must also stretch and recover with the fabric. Stretch fabrics are increasingly being used in garments, both low level ‘comfort’ stretch as used in stretch corduroy or denim where the amount of stretch may be up to about 30 per cent, and high level ‘action’ stretch for swimwear and dancewear where 100 percent or more is normal.
The elasticity of a sewn seam should be equal or slightly greater than that of the material.
Durability & Security:
Seams must also be durable to the kind of abrasion experienced in wearing and washing as well as secure against fraying apart or the unraveling of stitches. It is also important to minimize abrasion and wear by contact with outside agencies to promote durability.
Comfort:
The seam of the garments must be comfortable and will not create any problem during using.
A seam in a close-fitting or underwear garment must not present an uncomfortable ridge or roughness to the skin.
Factors on which Seam Properties depends:
The following are the factors on which seam appearance and performance depends-
Seam type, which is a particular configuration of fabric(s)
Stitch type, which is a particular configuration of thread in the fabric
Sewing machine feeding mechanism, which moves the fabric passes the needle and enables a succession of stitches to be formed
Needle, which inserts the thread into the fabric
Thread, which forms the stitch that either holds the fabric together, neatens it or decorates it
Seam Class:
The choice of seam type is determined by aesthetic standards, strength, durability, comfort in wear, convenience in assembly in relation to the machinery available, and cost. BS 3870: Part 2: 1991, referred to above, allows for eight different classes of seam, including some where only one piece of fabric is involved. Examples are the hem of a garment folded up on itself and a raw edge that has been neatened by means of stitches. This alters the traditional concept of a seam as a joint between fabrics.
Six seam classes were included in the 1965 British Standard and at that stage they were given names which usefully describe their constructions. Two more classes were added with the publication of the 1983 edition, but without the descriptive names, and the total of eight survives in the 1991 edition.
This is the most common construction seam on garments.
The simplest seam type within the class is formed by superimposing the edge of one piece of material on another. These seams are produced with a minimum of two pieces of components. Each component is limited on the same end.
A variety of stitch types can be used on this type of seam, both for joining the fabrics and for neatening the edges or for achieving both simultaneously.
Not all the seams can be sewn in one operation. The diagrams normally show the final version and it should be clear from the positions of the needles and the folding of the fabric if it was constructed in one step or several.
An example of this is the type of superimposed seam known as a French seam, which is completed in two stages. A similar, and in many cases equally acceptable, seam could be constructed using a folding device and a multi-needle machine, though only on a straight, rather than a curved, fabric edge.
An example of a superimposed seam with an additional component would be one that contained an inserted piping, and even here more than one construction is possible, as is shown in figure.
Figure: Superimposed seams.
Figure: French seams
Figure: Piped seams.
The simplest seam type in this class is formed by lapping two pieces of material.
These seams are produced with a minimum of two pieces of components. One component is limited on one end and the other is limited on other end.
In practice, this simple seam is not common in clothing because it causes problems with raw edges and at least one of the edges must be neatened in a decorative manner.
Much more common on long seams on garments such as jeans and shirts is the so-called lap-felled seam, sewn with two rows of stitches on a twin needle machine equipped with a folding device. This provides a very strong seam in garments that will take a lot of wear, though there is a possibility that the thread on the surface may suffer abrasion in areas such as inside leg seams.
The type of raised, topstitched seam is also technically a lapped seam, although at the beginning of its construction it appears to be a superimposed seam. It is often referred to as a welted or a raised and welted seam.
Figure: Lapped seam
Figure: Lap-felled seam
Figure: Welted seam
The seam is constructed by binding a component end with another narrow component.
The seam is produced with minimum of two pieces of component. One component is limited on one end and the other component is limited on both ends.
The simplest version of this class is again unusual as it cannot be constructed with self-fabric binding because of the problem of raw edges. It can, however, be made with a binding that has been constructed to a specific width or a contrasting colour of the garment fabric, has been cut into narrow strips.
A folding device can be used which folds the edges of binder and wraps the edge of the main fabric. A bound seam is often used as a decorative edge.
Examples in common use on underwear and leisurewear and on skirts, jeans and ladies’ trousers are shown in figures.
In part (i) is shown a common finish used on the neck edge of tee shirts, and also on the edges of men’s vests and briefs.
In Fig (ii), there is an insert of another cut strip. This would normally be in a contrasting color to the garment and both could contrast with the outer binding.
In Fig (iii), elastic has been included in a sufficiently stretched state to draw the edge of the garment in to a snug fit.
On all these seams, a stitch type would be used which has two needles and incorporates a thread passing between the needle threads on the underside and covering the raw edge of the fabric.
In Fig. 3.11(iv), a waistband, usually with an interlining fused to it, is bound on to the top of a skirt, jean or trouser using a folder and twin needle machine. The ends of the waistband require stitching separately.
Figure: Bound seams
Figure: Common bound seams
In this class, seams are referred to as flat seams because the fabric edges do not overlap.
They may be butted together without a gap and joined across by a stitch which has two needles sewing into each fabric and covering threads passing back and forth between these needles on both sides of the fabric.
Knitted fabrics are most commonly used because the advantage of this seam is that it provides a join that is free from bulk in garments worn close to the skin, such as knitted underwear.
The machine trims both fabric edges so that they form a neat join. Alternatively, various zig-zag stitches could sew back and forth between the fabrics which might then have a decorative gap between them.
Figure: Flat seams
This is the first of the two classes of seam which, in the old British Standard, were not regarded as seams at all and were given the name stitching’.
The main use of the seam is for decorative sewing on garments where single or multiple rows of stitches are sewn through one or more layers of fabric. These several layers can be folds of the same fabric. The simplest seam in the class has decorative stitching across a garment panel. One row would have little effect but multi-needle stitching is common.
Figure (i) shows twin-needle stitching with a ribbon laid under the stitches while part (ii) shows four rows of stitches.
Other possibilities, given by the right folding devices, are pin tucks, often sewn in multiples, and channel seams. These are shown in Fig (iii) and (iv). This type of pin tuck is different from the traditional version, which consists of a fold in the fabric sewn close to the edge. When multiple, parallel tucks are required, the original method is slow and potentially inaccurate. In the version shown here, the folder ensures the tucks are parallel as all the tucks are sewn simultaneously. The tucks must, however, be set to face one way or the other and a decision as to which must be made in relation to the design of the garment.
Figure: Decorative seams (i) 2 × 301, (ii) 4 × 401, (iii) pin tucks, (iv) channel seam
This is the other seam class that was previously called a stitching. Seam types in this class include those where fabric edges are neatened by means of stitches (as opposed to binding with another or the same fabric), as well as folded hems and edges.
The simplest is the fabric edge inside a garment which has been neatened with an overedge stitch, as shown in Fig. 3.14. In considering hems on the sleeves and lower edges of garments, there are many possibilities when the variety of stitch types that can be used is taken into account. A selection is shown in Fig. 3.15,
In Fig. 3.15, (i) is typical of the hem on a dress or a pair of trousers in a woven fabric, which has been neatened and then sewn up invisibly (blind stitched). In a knitted fabric the neatening might be omitted.
In (ii), a folding device is used in the construction of the hem of a shirt or a skirt lining; (iii) and (iv) show a method of folding an edge that is sometimes used on the buttonhole front of a shirt. Two different constructions are possible, the first one requiring the sewing to be done in two stages, the second one requiring a twin-needle machine.
Figure: Edge neatening.
Figure: Hemmed edges (i) 504/103, (ii) 301, (iii) 2 × 301, (iv) 2 × 401.
The remaining two seam classes in the 1991 British Standard are an addition to the original standard, added in the 1983 edition, to include seam types commonly seen in modern garment construction. No general descriptive title has been given to either of them.
Seams in this class relate to the addition of separate items to the edge of a garment part. They are similar to the lapped seam except that the added component has a definite edge on both sides.
Examples would be a band of lace attached to the lower edge of a slip as in Fig (i), elastic braid on the edge of a bra as in (ii), and inserted elastic on the leg of a swimsuit as in (iii)
An example where the additional item is self-fabric plus interlining is another version of the buttonhole band on a shirt, shown in Fig. 3.17. This is another instance where, by using two folders and a twin-needle machine, a complicated construction can be completed in one step. Without such machinery, achieving a similar, let alone identical, result would be very diffi cult.
Figure: Addition of separate items (i) 304 lace, (ii) 321, (iii) 406/504
Figure: Shirt buttonhole band, 2 × 401
The final seam class in the British Standard is another where only one piece of material need to be involved in constructing the seam.
The commonest seam type in this class is the belt loop as used on jeans, raincoats, etc. This is shown in Fig.(i). Also included in this class are belts themselves; two possible constructions for these are shown in Figs (ii) and (iii). The use on the belt loop of the stitch type mentioned before, which has two needles and a bottom covering thread, ensures that the raw edges are covered over on the underside while showing two rows of plain stitching on the top. The belt shown in (iii) is quicker and cheaper to construct than the one shown in (ii) but, as always, a special machine attachment is required to fold the fabric.
Figure: Belt loop and belts (i) 406, (ii) 301, (iii) 301.
Reference: Technology of Clothing Manufacture by Carr & Latham