Toyoda Gosei has developed automated sewing technology for the outer surfaces of automotive interior products, replacing a process that has historically depended on skilled manual workers. The advance addresses the challenge of stitching flexible outer layers into three-dimensional shapes, where precise needle and material control could not previously be mechanised.

The technology handles two stitch types critical to interior appearance: invisible stitches, which join materials from the back of the outer layer and are concealed from view; and exposed stitches, which provide both surface decoration and structural strength. Automatic sewing of flat fabric is well-established, but producing these stitches on three-dimensional interior components requires fine, continuous control of both needle movement and material positioning.

Toyoda Gosei achieved automation through improvements to the sewing machine itself, the fixture holding components in place, and the control software governing the process. The result minimises variability in sewing precision and delivers a more uniform finish across production volumes, reducing reliance on individual operator skill.

Toyoda Gosei plans to introduce the technology globally to strengthen its manufacturing position. The automation of craft-intensive interior finishing marks a broader shift in tier-one supplier strategy, as manufacturers seek to standardise quality-critical processes that have historically resisted mechanisation.

Source: Toyoda Gosei