From the 3D sketch
to a traceable finished product

The garment is designed in 3D before a single centimetre of fabric is cut. Textile 3D modelling software simulates drape, seam tension, and material behaviour (lycra, piqué cotton, terry, denim) with near-real-world fidelity. MARKAGENIE Collection designers create, adjust, and validate silhouettes in a virtual environment.

The 3D pattern is exported as a DXF/PLT file. Automatic grading generates all sizes (XS→XXL) in seconds. Nesting software then optimises piece placement on the fabric roll — reducing waste to 8–12% versus 18–25% with manual layout. The final file drives the CNC cutting table directly.

Two complementary technologies, each optimal for specific materials:

CNC Oscillating Knife — Heat-free. Ideal for lycra/elastane (BAÏNE swimwear), lightweight denim (shorts), multi-layer cotton jersey (GABIER stripes, stacks of 6–8 layers). Precision ±0.3 mm. Speed up to 1.2 m/s. Essential for heat-sensitive materials.

CO₂ Laser (existing MARKAGENIE) — Ideal for polyester/viscose (LAMINAIRE pareos and foutas): the laser fuses synthetic fibres as it cuts, eliminating fraying without requiring an overlock seam. Also used for decorative cuts and surface engravings on synthetic materials.

CNC flat seaming is the project's key industrial differentiator. Unlike conventional sewing (±2–4 mm, variable by operator), the CNC flatseam guarantees ±0.1 mm repeatability across the entire production run. The sewing head follows a G-code path, like a CNC milling machine. Speed: 3,500 stitches/minute versus 1,000 manually.

Priority application: BAÏNE swimwear in ECONYL® (recycled fibre). Flat seaming is the only seam comfortable in direct skin contact in water — a raised conventional seam would create friction and irritation.

MARKAGENIE operates a digital finishing fleet installed in 2024, near-new with very few hours of use. 9 CNC embroidery machines (8 two-head + 1 six-head managed by RAYNEN) enable simultaneous multi-station embroidery of logos, monograms, and nautical patterns. DTF printers (60 cm film transfer, available in fluorescent colours for beachwear visibility) allow complex pattern application on all materials, including lycra.

Roll sublimation (rotary calender) transforms polyester into full-width printing, with colours that penetrate the fibre rather than sitting on the surface — result: photographic rendering, exceptional wash resistance, unchanged hand feel. It is the reference technology for foutas (LAMINAIRE): a 200×90 cm roll in a single pass. The existing CO₂ laser then takes over for clean cutting of polyester edges.

Every production batch is digitally documented: fabric origin, material certificates (recycled ECONYL® for BAÏNE, GOTS organic cotton for GABIER), dimensional control per batch (10 pieces per 100 measured), reject rate. The QR code on the label links each piece to its batch record — accessible to the end buyer or ESG auditor.