From sketch to garment: a digital–first workflow for women’s trouser development utilizing CLO3D
Abstract
The contemporary apparel industry is undergoing a rapid digital transformation as manufacturers seek more efficient and sustainable alternatives to traditional, resource‑intensive physical sampling. This study presents a practice‑led, digital‑first workflow for women’s trouser development that systematically bridges creative ideation and industrial production. The research documents an end‑to‑end design pipeline encompassing four sequential phases: (1) hand‑drawn analog sketching for conceptual ideation, (2) technical vectorization through Adobe Illustrator CC, (3) 3D virtual prototyping and simulation using CLO3D to create a garment digital twin, and (4) empirical physical fabrication for validation. A single woman’s trouser style was developed as a representative case due to the fit‑critical complexity of lower‑body garments. The study evaluates the reliability of the digital workflow by comparing the CLO3D simulation with the final physical sample in terms of silhouette accuracy, seam alignment, fabric drape behavior, fit performance, and development efficiency. The results demonstrate a high degree of visual and morphological congruency between digital and physical outcomes, enabling a right‑first‑time physical sample without the need for iterative prototyping. Virtual strain and stress diagnostics accurately predicted ease distribution and fit comfort, while fabric drape behavior observed in the simulation closely corresponded to the physical garment under static conditions. The findings confirm that integrating analog creativity with digital engineering tools significantly reduces material waste, shortens development time, and enhances design accuracy. This research offers a replicable, industry‑ready framework for fashion educators and apparel professionals, with particular relevance to the Bangladesh Ready‑Made Garment (RMG) sector, supporting the adoption of sustainable, technologically advanced design development practices.