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Gerber produces costume replicas for “The Greatest Showman”

Projects | March 1, 2018 | By:

Telling the story of the “greatest showman on earth” requires exceptional sets and designs to convey the drama and excitement of P.T. Barnum and the birth of show business. For the film “The Greatest Showman,” 20th Century Fox wanted 50 sets of replicas of the costumes needed for every scene, which included elaborate performances. To meet the film’s release deadline, lead-time to produce the costumes was tight.

To get the job done, 20th Century Fox employed Gerber Technology to replicate the costumes. Gerber worked with Global Garment Engineering to digitally deconstruct the garments—without having to take them apart. The Gerber Silhouettetable digitally created pattern files from the original costumes in AccuMark®, a pattern design, grading, marker making and production planning software. The patterns were sent to AccuMark 3D, then draped on avatars to validate pattern pieces and review virtual samples.

Next, the pattern data was passed to AccuNest to create markers to ensure the optimum yield was achieved from more than 22 high-end fabrics. A cut ticket with a barcode was generated for each of the garments. The barcode transferred all the fabric and marker data needed to spread and cut each costume efficiently.

The fabric was loaded onto the GERBERspreader XLs125 where the spread details were automatically transferred. The material was passed on to be cut using the Gerber Paragon® HX. The cut ticket was scanned again to pull up the marker for each garment. After carefully managing the process and labeling the bundles of cut parts, they were packed and shipped for assembly. For more information, visit

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