ExactFlat®

Precision 3D to 2D Flatout

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What is ExactFlat?

ExactFlat is a specialized 3D‑to‑2D digital pattern‑making software, primarily used in apparel, furniture, marine, automotive, and other soft‑goods industries.

It functions as a powerful add‑in, notably for Rhino 3D, and SolidWorks, enabling a seamless workflow from 3D design to print‑ready 2D patterns.

Main Capabilities:

3D texture mapping & flattening: Apply graphics or textures to your 3D model, then “flatten” it into precise 2D panels while preserving visual alignment across seams and curves.

Strain/sag analysis: Detects and automatically relieves distortions, optimizing pattern accuracy.

Pattern engineering: Define seams, darts, notches, seam allowances, grain lines, and more—essential for manufacturable patterns.

Export-ready output: Exports cut lines and graphics together in formats like DXF, layered PDFs, or TIFF, compatible with digital printers and cutters.

Key Benefits:

Near‑zero waste & inventory – On‑demand manufacturing avoids excess stock.

Time and cost efficiency – Speeds up prototype-to-production time, often completing pattern generation in minutes instead of hours/days

Broad integration – Works with any digital textile printer, cutter, and CAD tool, most commonly Rhino 3D.

Who it’s for:

Ideal for product developers, pattern-makers, and designers in industries like fashion, marine upholstery, furniture, aerospace composites, inflatable structures, equipment covers and on-demand manufacturing setups.

Busy professionals use ExactFlat for 3D to 2D flattening and to make accurate, error free patterns faster than ever before.

ExactFlat WorkFlow

Step 1: Prepare 3D Model

  1. Import Your 3D Model into ExactFlat
  2. Adjust pattern splits using delete, split and join commands
  3. Optimize 3D mesh elements’ size, structure and count using ExactFlat’s Uniform and Adaptive Remesher.  

Step 2: Convert 3D to 2D

  1. Disassemble your 3D model into individual 2D pattern pieces
  2. Relax and dewrinkle initial strain on 2D pattern pieces
  3. Optimize fit by refining boundary edge length, surface area, and 2D geometry to ensure accuracy across all pattern pieces.

 Step 3: Finalize 2D Pattern

  1. Arrange 2D pieces to quickly visualize pattern assembly
  2. Add Pattern Features like seam allowances, alignment notches, and grain lines 
  3. Create export file in DXF or PDF formats 

Lear – Lear uses ExactFlat for automotive interiors and seating
https://www.lear.com/Site/Technology/seating.aspx

Hanse Yachts– Hanse Yachts uses ExactFlat for boat hulls and interiors
https://www.hanseyachtsag.com/hanse/gb/hanse/

Ball Aerospace – Ball Aerospace uses ExactFlat for satellite covers and wraps.  
https://www.ball.com/aerospace

Advanced Thermal – Advanced Thermal uses ExactFlat for the fabrication of turbine insulation systems.  
http://advancethermal.com/

Land Rover – Jaguar Landrover uses ExactFlat for automotive interiors.  
https://www.jaguarlandrover.com/

Diab – Diab uses ExactFlat for composite fabrication.
https://www.diabgroup.com

Eastman Chemical – Eastman uses ExactFlat for paint protection film.
https://www.eastman.com/pages/home.aspx

John’s Hopkins University – John’s Hopkins applied physics laboratory uses ExactFlat for composite engineering.  https://www.jhuapl.edu/

Raven Aerostar– Raven Aerostar uses ExactFlat for high altitude inflatables
https://ravenaerostar.com/

Yamaha Marine – Yamaha Marine uses ExactFlat for marine canvas and upholsetery
https://yamaha-motor.com/

Haworth Office Furniture – Howarth uses ExactFlat for upholstered furniture
https://www.haworth.com/na/en.html

Tesla – Tesla uses ExactFlat in the design and fabrication of composite parts
https://www.tesla.com

Cameron Balloons UK – Cameron Balloons use ExactFlat in the fabrication hot-air balloons and almost every conceivable type of lighter-than-air craft.

http://www.cameronballoons.co.uk

Lockheed Martin – Lockheed Martin uses ExactFlat for 3D to 2D conversion
https://www.lockheedmartin.com

Contact us for a quote or for any questions about ExactFlat.

ExcatFlat is a highly sophisticated, professional production tool with full training and support options available.