Case Study: Toyota Boshoku America achieves faster prototyping and improved cutting accuracy with Lectra's VectorAutoFX

Toyota Boshoku America - Customer Case Study

Toyota Boshoku America, a leading supplier of automotive interior systems with an R&D prototyping center in Novi, Michigan, faced growing complexity and tighter timelines in seat development. New features (heating/cooling, occupant detection, airbags) and industry-level tolerances, plus a shortened concept-to-prototype window (~4 weeks), made the previous hand-cutting process slow (2–3 hours per trim cover) and insufficiently accurate.

To address this, the company adopted Lectra’s VectorAutoFX automated cutter, integrated with Formaris pattern-making and Diamino marker software. The system delivers production-level accuracy (better than their plotter), smooth tight-radius cuts, and much faster throughput (parts cut in minutes, 5–10 covers at a time), reducing design changes, ensuring prototypes match production, and improving material versatility and overall productivity.

Toyota Boshoku America

Jon Gill

Lead Engineer