Innovation in digital leather processing
Swiss-based cutting technology provider Zünd recently unveiled further innovative solutions for the leather industry, showcasing advances in automation, precision, and workflow efficiency.
These, including the compact G3 cutter and augmented reality (AR)-assisted interactive nesting, mark significant progress in the adoption of smart factory principles in wider leather processing. With a focus on digitisation and sustainability, they continue to redefine production standards in an industry that balances tradition with technological skill.
The introduction of interactive nesting using augmented reality (AR) demonstrates the transformative potential of digital tools in leather processing. Described by Zünd as “an interactive experience that augments the real world with computer-generated perceptual information and combines the physical environment with virtual elements”, AR has been widely adopted in industries, such as gaming, training, and manufacturing, and its application in the wider leather handling industries addresses the unique challenges of working with natural materials, including irregularities, variable textures, and treated surfaces.
Using AR glasses, operators can visualise leather hides and position parts in real-time. This patented workflow, developed in collaboration with its software partner Mind, incorporates manual nesting techniques. Operators can rotate, arrange, and place parts to maximise material utilisation while following specific nesting criteria. Katrin Dotzauer, Zünd's global market manager for furniture, fashion, and outdoor, shared insights with Footwearbiz about this technology, particularly in relation to the luxury leathergoods sector. She noted that AR systems are generating significant interest, as the ability to picture the production process in real-time is viewed as a valuable enhancement to ensuring quality. She highlights that, although the AR process may be slower than fully automated digital nesting systems, the leathergoods market often uses more expensive hides in their production. As a result, physically marking materials for fault detection is not always preferred. By adopting augmented reality, users can maximise material efficiency while still maintaining quality. As noted, an additional benefit of the AR system is, unlike traditional projection systems, which often struggle with reflective or treated surfaces, AR excels in such conditions, providing precise placement and minimising material waste. With high gloss hides and skins such as patent leather or glazed crocodile skins, projected imagery is often “invisible” and whilst some laser systems can be used, the stability of the outlines are often problematic.
At the 2024 SIMAC exhibition, Zünd demonstrated the abilities of AR in conjunction with the G3 cutter, a compact yet versatile machine tailored to the specific demands of leathergoods processing. Featuring a 227 x 280 cm (89 x 110 inches) working area, the G3 cutter combines precision with practicality, making it ideal for working with medium-sized hides and, despite its modest footprint, the system is designed to streamline the entire workflow, from nesting and cutting to parts removal.
The cutter operates using a three-zone process, dividing the workflow into sections for loading, cutting, and removal. This arrangement allows simultaneous operations, enabling new hides to be loaded and graded while finished parts are removed, without interruption to the cutting process, and boosting overall productivity by minimising downtime and optimising resource use. Controlled via Mind software, the system ensures centralised management of tasks and supports up to three tools, providing the flexibility needed for a range of leather handling applications.
Advancing automation with leather grading
In a move to further digitise leather processing, the Swiss company has also recently announced a partnership with Mindhive Global, a leader in automated leather grading. This collaboration aims to develop high-speed, precision grading solutions for finished leather. Automated grading offers consistent quality, a key requirement for industries such as footwear, furniture, automotive interiors and luxury goods. By integrating Mindhive’s grading technology with its cutting systems, Zünd hopes to reinforce its position as a total solutions provider for the leather industry.
Towards a smart factory for leather processing
Zünd’s innovations align with the broader industry shift towards smart factory principles, where automation, data integration, and intelligent systems drive efficiency and sustainability. In the leather industry, this transformation involves streamlining traditional processes, minimising material waste, as well as the precision required for premium products.
By combining compact yet versatile cutting solutions like the G3 cutter with digital tools such as AR-assisted nesting and automated grading, Zünd is enabling leather manufacturers to embrace this new landscape, catering to both high-volume production and specialised luxury markets.
The lightweight headset allows the user to visualise the work environment where virtual elements are projected into their field of view.
All Credits: Zünd
