Creative Design: Professional

Gradeable Zero-Waste Heathcare Scrubs: Prototype Development for Mass Production

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Abstract

The apparel industry’s urgent need to reduce textile waste has prompted the exploration of scalable zero-waste (ZW) design solutions. The Carrico Zero-Waste Banded Grading (CZWBG) method enables gradable, size-inclusive ZW patterns through the insertion of variable-width bands at key seamlines, allowing garments to expand across sizes without fabric waste. This study applied CZWBG to healthcare scrubs to test its potential in mass-produced functional apparel. Using a problem-based design research approach, the project incorporated user feedback on functionality, iterative digital pattern development in Illustrator and Browzwear, and small-batch production testing. Constructed in 100% cotton, the design maintained utilitarian aesthetics, ergonomic fit, and manufacturing efficiency while remaining fully ZW. Results confirm that CZWBG can support scalable, size-inclusive, and sustainable workwear. This study extends ZW methodology beyond experimental contexts, demonstrating a replicable system for industrial production of functional garments that balance sustainability, performance, and aesthetic consistency.

Keywords: Zero-Waste, grading, scrubs, mass production

How to Cite:

Rougeaux-Burnes, A., Moretz, C. A., Dragoo, S., McKinney, E., Carrico, M. & Stannard, C. R., (2025) “Gradeable Zero-Waste Heathcare Scrubs: Prototype Development for Mass Production”, International Textile and Apparel Association Annual Conference Proceedings 82(1). doi: https://doi.org/10.31274/itaa.21775