The traditional fashion industry generates a significant amount of waste throughout the production process, highlighting the growing importance of research aimed at achieving sustainable fashion. In response, various efforts have been undertaken acros...
The traditional fashion industry generates a significant amount of waste throughout the production process, highlighting the growing importance of research aimed at achieving sustainable fashion. In response, various efforts have been undertaken across academia and industry to promote sustainability in material usage, production methods, and industrial systems. This study aims to develop a zero-waste pattern cutting (ZWPC) technique that enables sustainability at the pattern and cutting stages. In particular, it seeks to address the limitations of existing ZWPC approaches, which often face difficulties in industrial application due to discrepancies from ready-to-wear (RTW) styles and incompatibility with conventional production systems. To this end, a pattern cutting method utilizing apparel CAD commonly used in the fashion industry was developed as an alternative approach that can be integrated into RTW manufacturing environments. The main findings are as follows. First, a zero-waste women’s RTW jacket pattern was developed using apparel CAD. Second, a comparative analysis with a conventionally designed control pattern confirmed reductions in both fabric consumption and material waste. Third, industry professionals evaluated the experimental pattern through sample production and in-depth interviews, verifying its practical applicability across each stage of the manufacturing process. Finally, the advantages and limitations of the proposed method, as well as its applicability to the RTW industry and educational contexts, were discussed. This study is significant in that it presents a ZWPC approach that maintains existing RTW aesthetics and industrial infrastructure. By expanding the scope of future research and establishing clearer guidelines for industrial and educational applications, this approach has the potential to develop into a practical and sustainable fashion design methodology applicable to real-world production settings.