OPTIMISING FASHION PROTOTYPING FOR ZERO-WASTE SAMPLING

The conventional fashion prototyping process generates significant material waste, time consumption, and production costs due to repeated development of physical samples. This study explores a sustainable approach to minimize waste during the sampling stage by integrating digital prototyping techniques with traditional textile practices. The research incorporates natural dyeing using Indigo and Madder Red, handloom weaving, and digital simulation using APEX software. Physical fabric samples were developed and compared with digitally simulated fabrics based on parameters such as yarn count, fabric density (EPI and PPI), weave structure, and cloth cover factor. The findings demonstrate that digital simulation can replace up to 80–90% of physical sampling in early design stages, significantly reducing fabric waste, dye consumption, and production time. The study highlights that combining traditional craftsmanship with modern digital tools offers a practical pathway toward zero-waste sampling and sustainable fashion product development.