Software-Based Optimization of Bias Tape Production for Sustainable Apparel Manufacturing

In the ready-to-wear industry, accurate estimation of fabric consumption is essential for cost efficiency, particularly for bias tapes, which constitute a notable share of overall material usage. Although bias tape is widely used across the apparel industry, no formal mathematical model exists for calculating its consumption, and current practices rely heavily on technician experience and sample garments. Because bias tape consumption in multi-size garment manufacturing involves geometric adjustments and decision steps that are not captured by existing methods, this study develops the first mathematically structured model for bias tape estimation and implements it in a software tool, providing a more reliable and standardized alternative to manual calculations. The model was validated using data collected in a real production environment from 20 garment models (13,122 units), and statistical analyses confirmed that the software produced significantly more accurate estimates than conventional methods, resulting in fabric savings of up to 39.5%. These findings demonstrate that the system enhances material utilization and supports data-driven planning in apparel manufacturing.