Large cargo parachutes consist of ribbon type canopies that mus be sewn using four needle lockstitch machines. Past and current four needle lockstitch machines could sew a maximum width of 1 1/2", requiring multiple passes if wider ribbons were to be used. We developed sewing workstation using two fully synchronized large bobbin needle feed sewing machines, that allows for the use of wider webbing, increasing the strength of the parachute, while significantly reducing the fabrication time.

Industrial conveyor belts must have a variety of different drive extrusion profiles stitched to belting for various conveyor drive systems. The difficulty in keeping the extrusion in place while sewing in the past resulted in making multiple passes using a single needle machine in order to sew the extrusion onto the conveyor belting. We fabricated custom sewing parts (presser feet, feed dog and needle plates) to accomadate the different profile of each extrusion. A thirty minute change out of these sewing parts, performed by the plant maintenance staff, allows fabrication of belts using the different profile extrusions on the same sewing workstation.

A large manufacturer struggled to produce barrel-type tote bags efficiently. The bags were closed with heavy chain roll zipper that had to be sewn to the body of the bag using lock stitching. Previously, the zipper had been sewn into the bag one side at a time on a flatbed machine. We were approached with the problem of how to sew both sides of the zipper onto the body of the bag in one operation. A conventional feed off the arm machine would not allow for the required needle spacing of 3/4". We fabricated a custom set of sewing parts, zipper attachment and folders for use on a double needle post bed machine the workstation allows both sides of the zipper to be sewn in one pass through the sewing machine.

A fabricator of large tensile structures needed to sew multiple layers of woven polypropylene, cable & reinforced webbing. After the fabric was laid out and cut, attempts at sewing and stapling of components was inefficient and time consuming, as the panels were often over 100' long. We examined the seam construction, and suggested that instead of moving the material through the sewing machine that the sewing machine could be moved along the fabric. We constructed a sewing workstation controlled by a start & stop button, rather than a conventional treadle. Use of a servo motor and custom built stand made it easy to move the machine along a fabric panel and sew the reinforcing cable & webbing without having to move the panels.