Fabric Utilization of Women’s Kameez Designs with Different Types of Sleeves in the Apparel Industry

The apparel industry is changing dynamically and quickly to manufacturing sustainable fashion products and the development of sustainable design strategies that minimize material consumption at the source. This study addresses a critical research gap by quantitatively evaluating the impact of fusing traditional South Asian garment construction (the kameez) with varied, Western-inspired sleeve geometries on key manufacturing metrics. Thirty-three distinct women’s garment styles, comprising three kameez types (simple, princess-cut, open-front) each paired with eleven different sleeve designs, were developed in the apparel industry to study the effect of fabric efficiency, wastage, and cost-effectiveness. The virtual patterns and markers were drafted and accomplished through Garment Gerber Technology (GGT) software to analyze fabric consumption, fabric efficiency, and cost-effectiveness. The results revealed that paneled kameez styles, such as the princess-cut and open-front, are significantly more material-efficient, achieving average fabric efficiencies of up to 83.95%, compared to the monolithic simple kameez, which averaged only 75.68%. Among sleeve types, multi-constructions like the slit sleeve and cuff sleeve proved most efficient (achieving up to 86.91% efficiency), while voluminous, single-piece designs like the umbrella sleeve consumed the most fabric and were the least efficient. Open-front kameez slit sleeves (OFSL3), simple kameez slit sleeves (SSL3), and princess-cut kameez slit sleeves (PCSL3), were better and more sustainable selections since they were most efficient in fabric efficiency (i.e., 86.91%, 86.17%, and 86.09%). Furthermore, the simple kameez style has the highest fabric wastage (above 22%), while the princess kameez style has the least (below 19%). The simple kameez slit sleeves design (SSL3) has the minimum wastage, while the simple kameez umbrella sleeves design (SSL4) has the maximum wastage. From a cost perspective, the open-front kameez slit sleeve (OFSL1) was identified as the most economical design, whereas the simple kameez with an umbrella sleeve (SSL4) was the most expensive. Statistical analysis confirmed that the differences between kameez styles were significant (p < 0.05). Thus, adoption of specific, sustainable, deliberate design choices and incorporating paneling into the garment body and utilizing multi-piece sleeve constructions offer a quantifiable and strategic approach for manufacturers to reduce material waste, optimize fabric utilization, and improve production cost-effectiveness.