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Zero-waste innovation

We want to save the world's valuable textiles. That is why we produce with less than 1% wastage and thus save around 20% of material in the cutting process. With a resource efficiency of over 99% and a waste reduction of less than 1%, Free Prisoner's designs for all collections embrace zero-waste principles. Besides draping techniques, Free Prisoner created innovative patterns that incorporate curves to ensure an optimal fit on the body. The pattern pieces interlock so that waste, or textile scraps, are significantly minimized compared to industry standards.

Black is waste, about 20% in this trouser.

Less fabric needed with zero-waste pattern

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Zero-waste pattern

Conventional pattern

This is important because 60 billion m2 textile of the 400 billion produced annually is left on the cutting room floor. Most of these leftovers end up in landfills in Asia. Far from sight, far from mind, far from where it could and should be used. That means 15% of the energy and money spent on growing, harvesting, weaving and shipping is spent on nothing. Because of this textile waste, a lot of extra unnecessary pollution of chemicals, water and CO2 is produced. The 15% waste is the consequence of reckless use of curves in conventional pattern making. As cutting and manufacturing are often outsourced to producers in developing countries, occidental fashion designers never have to face the amount of waste created by their own collections. It is a secondary concern to them,
but not to Free Prisoner.

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Outcome of the pattern cutting example. 

An impeccable fit is guaranteed by the complex nesting of the curves of the patterns.

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