Sewing is the major contributor to the manufacturing of protection wear for
the survival of early human civilization against extreme weather conditions. Mechanized sewing witnessed developments during the middle of the 19th century, and tedious handwork was replaced by sewing machines. Despite the modernization of sewing machine technologies, speed, material thicknesses, automation, and the introduction of AI in sewing, there is a longstanding problem of heat loss along stitch lines. The sewing material is compressed
by the sewing thread, and this compression results in a bridge between the human body and the external cold environment. Garment technologists identify this problem and due to the lack of any technological solution, the problem is solved through complex material handling methods. A new sewing technological solution has been developed to solve this problem, called spacer stitching, which addresses the problem of compression along stitch lines. Two baffled jackets with sewn-through methods are prepared, one with the spacer stitching technology and the other with conventional sewing. Thermal resistance and insulation efficiency are evaluated using the Thermetrics thermal manikin “Sonny” under dynamic (walking) conditions to analyze the thermal resistance difference between the two types of sewing methods as well as the effects of motion on insulation. The results reveal that the jacket made with spacer stitching demonstrates significantly higher thermal resistance and enhanced wearer comfort compared to that produced using conventional
methods. Additionally, variations in thermal resistance are observed across different zones of the thermal manikin. These findings highlight the potential of spacer stitching to improve thermal insulation and revolutionize high-performance outerwear design.