Perfect Sewing on Perforated & Embossed Surfaces - Live at Automotive Interiors Expo

Dear Friends of ZSK Interiors Solutions,

Automotive interiors demand a level of precision that leaves no room for compromise. Perforated leather, embossed surfaces, complex weld seams - every stitch must align to tolerances that conventional embroidery systems simply cannot achieve.

ZSK's Optical Positioning Systems OPS2 and OPS3 were built for exactly this challenge. At Automotive Interiors Expo 2026 in Stuttgart, we invite you to see both systems running live on real automotive surfaces and to speak with our engineers about your specific production requirements.

OPS2 & OPS3 - Vision-Guided Precision for Automotive Surfaces

ZSK offers two complementary optical positioning systems, each engineered for a specific range of automotive surface challenges. Together, they cover the full spectrum of interior embroidery and sewing applications.

Across both systems: up to 0.1 mm positioning accuracy · real-time compensation for material stretch and shrinkage · integration with EPCwin digitising software and ZSK automation tools.

Optical Positioning System OPS2 is the proven specialist for perforation detection. Using contrast-based 2D recognition, it precisely locates perforations in leather and technical textiles.

The integrated edge detection measures the actual cut piece, compensates for cutting tolerances, and ensures the exact placement of lock stitches within the seam allowance - regardless of how the material was cut.

OPS2 supports sewing directly within perforation gaps, opening up decorative and functional possibilities that standard systems cannot achieve. A Click-to-Stitch workflow via QR code loads the correct design automatically, reducing setup time and eliminating operator errors.

Where OPS2 reads contrast, OPS3 reads structure. A dynamic line-scan sensor captures the material surface topographically in 3D, detecting embossed logos, prints, and weld seams through height difference alone — independent of contrast.This makes OPS3 the right tool for surfaces where 2D detection reaches its limits.

Dedicated filters for Alcantara, suede, and Dinamica eliminate interference from fibre dust for reliable perforation detection even on sensitive materials. As with OPS2, a Click-to-Stitch workflow via QR code is included for fast, error-free job setup.

The Complete ZSK Production System

At our stand, you will see OPS2 and OPS3 as part of a fully integrated production environment:

• Combined sewing & embroidery on a single machine head - up to 24 needles, processing both embroidery and sewing threads from 15 to 210 tex, on material thicknesses up to 20 mm
• EPCwin digitising software & ZEPL automation - from first design to repeatable series production
• Auto Select Bobbin Changer & Groz-Beckert needle systems - engineered for continuous reliability on demanding automotive materials

Made in Germany. Built for the tolerances that premium automotive interiors demand.

Visit us in Stuttgart

Automotive Interiors Expo 2026 Powered by Vehicle Tech Week Europe

Come and meet our team, and experience OPS2 and OPS3 in action.

Would you like to schedule a personal meeting at the show in advance?
We are happy to arrange a dedicated time slot for you.