Gerber Produces Costume Replicas for the New Film The Greatest Showman.

In every aspect of the fashion world, digitalization is driving the demand to bring new styles to market faster. Costume replicas are costly and, in the past, they were all done by hand. But recently Gerber Technology combined forces with Global Garment Engineering and 20th Century Fox to replicate costumes worn by Hugh Jackman, Zac Efron, Michelle Williams, Rebecca Ferguson and Zendaya in the upcoming film The Greatest Showman. By leveraging Gerber’s integrated digital solutions, they can now be done in a fraction of the time and at a much lower cost.

The challenge 20th Century Fox presented was to produce 50 sets of replicas of beautiful and complicated costumes in a very short time frame (without taking them apart) to support the film’s release.

top coat pattern pieces

Prior to project kickoff, photographs, technical sketches, measurements, component details and assembly instructions were compiled within YuniquePLM® to ensure planning, management and tracking of each essential step was executed properly and timelines were met. The job started by digitizing each garment on the Silhouette™ table, where pattern files were instantaneously created in AccuMark®. The patterns were simultaneously passed into AccuMark 3D, where they were draped on avatars to validate pattern pieces and review virtual samples ensuring the patterns would accurately and precisely be sewn together to create perfect replicas.

trapeze outfit

After the patterns were validated in AccuMark 3D, data was passed to AccuNest™ to create markers ensuring the optimum yield was achieved from the beautiful and expensive fabrics needed to produce the costumes. Over 22 diverse fabrics were spread on the GERBERspreader™ XLs125 and cut using the Gerber Paragon®. After carefully managing the process and labeling the bundles of cut parts, they were packed and shipped to New York for assembly.

These exact replicas of the costumes worn by Hugh Jackman, Zac Efron, Michelle Williams, Rebecca Ferguson and Zendaya will be revealed at various locations around the globe to celebrate the magic of the film.