As the young generation's rigid demand for living space continues to grow, there is a growing demand for furniture with small space, high cost performance and integrated design. This trend, coupled with the government's increasingly stringent environmental protection standards, is driving leather furniture manufacturers to transform to digitalization and green manufacturing to achieve dual optimization of cost-effectiveness.

Leather nesting and cutting: manual and automatic analysis

Traditionally, making a standard leather sofa requires patching and cutting leathers of different sizes and qualities for various parts of the sofa. In this process, craftsmen face challenges such as material dislocation and waste caused by manual patching and cutting. This method is not only inefficient, but also has low material utilization. In addition, the inheritance of these skills is also difficult, which makes it challenging to find experienced craftsmen.

The use of digital nesting equipment can centrally process data, quickly provide multiple nesting solutions through cloud computing analysis, greatly reduce material waste, and achieve efficient cutting. This integrated nesting and cutting solution not only saves a lot of time and labor costs, but also increases the leather utilization rate to more than 85%.

Moreover, the nesting equipment and cutting equipment are seamlessly connected to achieve nesting + cutting in one step, saving a lot of time and labor costs.

Digital leather nesting + cutting solution

For leather furniture nesting + cutting, AOL provides a series of intelligent equipment to optimize nesting and cutting processes, significantly improving production efficiency and material utilization.

AOL-3235 equipment can realize efficient digital nesting of leather materials and save leather to the maximum extent.

AOL-3235 realizes intelligent cutting of large-area leather surfaces, dual-head asynchronous operation, automatic feeding + projection, and greatly reduces labor costs.

Here´s a closer look at how CNC machines can efficiently produce up to 20 different sofa styles in just 10 hours.

Step 1: Digital Pattern Creation

The process begins with the digitization of the paper pattern. Traditional paper templates need to be scanned using a digital device to create an electronic version of the cut piece at an exact 1:1 scale. Digitization is essential as it ensures that the exact size and shape of the original design is preserved, which is crucial to achieving a high-quality end product.

Step 2: Edit and Adjust

Once the drawings are digitized, the next step is to use professional furniture design software to edit and adjust the size and quantity of the parts as needed. This flexibility is especially important for custom furniture orders, where the size of custom furniture often varies depending on the customer's requirements or space constraints.

Step 3: Smart Nesting

Once the pattern is finalized, the software automatically performs nesting operations. This intelligent function optimizes the layout of the pattern on the material to be cut (such as fabric or leather) to minimize waste. The smart nesting algorithm takes into account multiple factors, including the texture of the fabric, the number of layers required, and the best fit, thereby minimizing material consumption while maximizing production efficiency.

Step 4: Automatic Cutting

Once the pattern is prepared and optimally arranged, the CNC cutting machines go to work. These machines are equipped with advanced cutting tools that can handle multiple layers of fabric or leather at the same time. The cutting process is fully automated, which not only speeds up production but also ensures consistent quality across all parts. The precision of the CNC machines ensures that every cut is clean and exactly to the design specifications.

Step 5: Assembly and Finishing

After the parts are cut, they will enter the assembly stage and be stitched according to the design specifications. The high precision of CNC cutting ensures the simplicity of the assembly process and all parts fit perfectly, thereby increasing the speed of the final assembly process.

We insist on using intelligent equipment [nesting + cutting] to ensure the high consistency and accuracy of the product, and ensure that each component is manufactured according to the design specifications, so as to maintain the consistency and comfort of the product. In the end, the improvement of seat comfort solved the problem of small batch customized production!

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