The work deals with the problem of excessive generation of textile waste in the fashion industry, with a special focus on the stages of design and production of clothing. Modern methods and digital technologies that enable waste minimization are analyzed, including zero-waste design, 3D simulations, digital prototyping and artificial intelligence. Special attention is paid to CLO 3D and Audaces software solutions, which enable more precise tailoring, optimization of material consumption and more efficient production of clothing. The implementation of these technologies contributes to sustainability, reducing the negative impact on the environment and moving towards a circular model of the fashion industry.

The purpose of this paper is to evaluate the thermophysiological comfort of pineapple bio-based nonwoven material as a sustainable alternative to natural leather and synthetic polymer-coated materials by analyzing both the objective parameters of the material and subjective user feedback by wearing a skirt made from the same material. Considering the increasing demand for sustainable materials alternatives, the study aims to determine whether this material can offer acceptable comfort during wear. The research included two commercially available pineapple, bio-based, nonwoven materials that differed in their finishing. Sample S1 contained 5% Bio-PU and 5% conventional PU, and sample S2 contained 10% conventional PU. Objective parameters such as thermal resistance (R_ct), water vapor resistance (Ret) and air permeability were measured. For the subjective evaluation, ten female subjects wore the pineapple bio-based material skirts under controlled environmental conditions. Sample S1 showed lower R_ct values and slightly lower Ret combined with higher air permeability, which correlated with better subjective comfort evaluation. Although both samples showed high R_et values (S1 = 60.57 Pa²/W; S2 = 84.80 m²K/W) indicating limited vapor transfer, sample S1 was perceived as more comfortable, which was effected by better air permeability (S1 = 11.3 mm/s; S2 = 2.65 mm/s). Overall, S1 is more suitable for indoor use and for a shorter wear duration, while S2 may be better for cooler outdoor environments.

Considering the rapid changes in the fashion and clothing industry, digital technologies represent an important tool for improving the efficiency and sustainability of production processes. This paper explores the application of 3D software tools in the skirt design process, with a particular focus on time savings, waste reduction, and visualization capabilities prior to making the first trial sample. Using CLO 3D software, a digital model of the skirt was developed and compared with the conventional approach in Modaris software. The analysis includes a comparison of the duration of production, flexibility during changes, visual control. The conducted analyse show that the 3D construction and visualzation enables faster design iteration and a reduction in the number of sewn first samples, which contributes to sustainability through a more rational use of materials. It can be concluded that the integration of 3D programs for the construction and visualization of garments represents a significant step towards the digital transformation of the fashion industry.

The paper emphasizes that the life cycle and production process of an article of clothing includes a large number of stages such as: production of raw materials and fibers; production of fabrics, knitwear, non-woven textiles, etc.; design; tailoring, sewing and finishing of clothes; distribution; retail; phase of use and disposal of clothing-recycling or disposal. All this leads to the textile industry creating tens of millions of tons of textile waste annually on a global scale. Therefore, the need to find a solution to the complex production process of clothes in order to reduce the negative impact of the fashion industry on the environment is becoming more and more important. Various strategies for solving the problem of textile waste are also described. In the end, the conclusion is drawn that fashion companies pay more and more attention to the improvement of the products themselves as well as to the extension of the lifespan of the products themselves. For a typical textile product, 7 characteristic life stages through which it passes are described: concept and design stages, engineering stages, production stages, distribution and application stages, use and service activities (dry cleaning and washing), second life cycle stages (reuse) and end-of-cycle stages (recycling or disposal).

The development of digital technologies has enabled the analysis of the behavior of clothing products in a virtual environment using 3D simulation. One of the important factors in these simulations is the digital avatar, whose characteristics can affect the interaction between clothing and the body. The aim of this work was to examine the influence of the avatar type and its surface characteristics on the clothing fit and stress distribution during 3D simulation. The simulation was conducted in the Browzwear V-Stitcher software on a dress model made of 100% cotton rib knit (2×2 rib) and interlock. The analysis included two types of avatars (hard and soft Olivia) and three types of avatar surfaces (human, plastic and fabric). The results show that the highest stress values are recorded in the chest area, while the differences between the avatar surfaces are relatively small. At the same time, it was observed that the deformability of the soft avatar affects the contact between clothing and the body and allows for a more natural fall and draping of the material compared to a rigid avatar.

Ultrasonic technology is successfully used manufacturing wide variety of apparel and technical textile goods.It is suitable for synthetic fabrics due to their low melting points and ability to absorb ultrasonic energy efficiently. Two main types of ultrasonic textile equipment used are: roll seam machines and platen presses. Using ultrasonic technology can be performed textile seam welding, cutting, lamination, punching, embossing, lacing, riveting, inserting. Comparing with traditional sewing method ultrasonic technology can ensure several advantages: higher processing speed, higher strength of seams, and ability to create waterproof and airtight seams. Advantages that support sustainable garment manufacturing goals are: reduced waste and energy use, improved fabric recyclability, improved workplace environments for the industrial workforce.