Abstract: An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. A head for applying stitches to a decorative component having a three dimensional configuration, including: a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to provide a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion, the post assembly being operatively coupled to the head via a cylinder arm assembly and a downshaft assembly; and wherein the cylinder arm assembly is rotated in a synchronized manner with a rock frame through mechanical linkage connecting a rock frame drive shaft to the cylinder arm assembly.

Abstract: An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. A head for applying stitches to a decorative component having a three dimensional configuration, including: a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to prove a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion, the post assembly being operatively coupled to the head via a cylinder arm assembly and a downshaft assembly; and wherein the cylinder arm assembly is rotated in a synchronized manner with a rock frame through mechanical linkage connecting a rock frame drive shaft to the cylinder arm assembly.

Abstract: An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. The apparatus having a head with a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to provide a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; and a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion.

Abstract: An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. The apparatus having a head with a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to provide a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; and a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion.

Abstract: A method of applying stitching to an outer skin layer of an interior component is provided herein, the outer skin layer having a contoured surface.

Abstract: An apparatus for stitching a component is provided. The apparatus having: an awl bar assembly, the awl bar assembly having an awl configured to be moved from a withdrawn position to an inserted position; a needle bar assembly having a needle, the needle movable between an inserted and a withdrawn position, the needle bar assembly being pivotally mounted to a pivot; and a biasing member coupled to the needle bar assembly, the biasing member being arranged to pivot and align the needle bar assembly in response to the needle being moved to the withdrawn position.

Abstract: A method of applying stitching to an interior component is provided herein. The interior component having only a single layer of a substrate layer. The method including the steps of: a) penetrating substrate layer with an awl of a sewing head to form a piercing therethrough; b) retracting the awl from the substrate layer; c) inserting a needle of the same sewing head through the piercing through the substrate layer to grasp a thread positioned on a show surface of the outer skin layer; d) pulling the thread through the substrate layer; e) looping the thread with a previous stitch passed through the substrate layer; f) advancing the sewing head to another position with respect to the interior component, wherein a backside of the substrate layer is free of obstructions; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

Abstract: A method of applying stitching to an outer skin layer of an interior component is provided herein, the outer skin layer having a contoured surface.

Abstract: A method of applying stitching to an outer skin layer of an interior component is provided herein. The method including the steps of: a) penetrating the outer skin layer at an entry point on a first surface of the outer skin layer with a curved needle; b) exiting the outer skin layer at an exit point on the first surface with the curved needle, wherein the steps of penetrating and exiting cause a first thread to pass through the entry point and the exit point on the outer skin layer; c) grabbing the first thread with a hook located proximate to the exit point; d) retracting the needle through the exit point and the entry point while pulling a second thread through the exit point via the first thread to form a stitch; e) advancing the outer skin layer to a new location with respect to the needle and hook; and f) repeating steps a-e until a predetermined amount of stitches are applied to the outer skin layer.

Abstract: An apparatus for stitching a component is provided. The apparatus having: an awl bar assembly, the awl bar assembly having an awl configured to be moved from a withdrawn position to an inserted position; a needle bar assembly having a needle, the needle movable between an inserted and a withdrawn position, the needle bar assembly being pivotally mounted to a pivot; and a biasing member coupled to the needle bar assembly, the biasing member being arranged to pivot and align the needle bar assembly in response to the needle being moved to the withdrawn position.

Abstract: A method of applying stitching to an interior component is provided herein. The interior component having only a single layer of a substrate layer. The method including the steps of: a) penetrating substrate layer with an awl of a sewing head to form a piercing therethrough; b) retracting the awl from the substrate layer; c) inserting a needle of the same sewing head through the piercing through the substrate layer to grasp a thread positioned on a show surface of the outer skin layer; d) pulling the thread through the substrate layer; e) looping the thread with a previous stitch passed through the substrate layer; f) advancing the sewing head to another position with respect to the interior component, wherein a backside of the substrate layer is free of obstructions; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

Abstract: An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. The apparatus having a head with a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to provide a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; and a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion.

Abstract: A method of applying stitching to an outer skin layer of an interior component is provided herein. The method including the steps of: a) penetrating the outer skin layer at an entry point on a first surface of the outer skin layer with a curved needle; b) exiting the outer skin layer at an exit point on the first surface with the curved needle, wherein the steps of penetrating and exiting cause a first thread to pass through the entry point and the exit point on the outer skin layer; c) grabbing the first thread with a hook located proximate to the exit point; d) retracting the needle through the exit point and the entry point while pulling a second thread through the exit point via the first thread to form a stitch; e) advancing the outer skin layer to a new location with respect to the needle and hook; and f) repeating steps a-e until a predetermined amount of stitches are applied to the outer skin layer.

Abstract: An apparatus for stitching a component is provided. The apparatus includes an awl bar assembly coupled to a first drive device. The awl bar assembly is moved from a first position to a second position along the stitch path with an external drive device. A second drive device is coupled to the first drive device. A needle bar assembly is provided having a needle. The needle moves between an inserted and a withdrawn position, the needle bar assembly being pivotally coupled to the second drive device, the needle bar assembly moves from the first position to the second position with the same external drive device driving the awl bar assembly. A biasing member is coupled to the needle bar assembly, the biasing member being arranged to pivot and align the needle bar assembly in the second position in response to the needle bar being moved to the withdrawn position.

Abstract: A method of applying stitching to an interior component is provided herein. The interior component having only a single layer of a substrate layer. The method including the steps of: a) penetrating substrate layer with an awl to form a piercing therethrough; b) retracting the awl from the substrate layer; c) inserting a needle of a robotic sewing head through the piercing through the substrate layer to grasp a thread positioned on a show surface of the outer skin layer; d) pulling the thread through the substrate layer; e) looping the thread with a previous stitch passed through the substrate layer; f) advancing the robotic sewing head to another position with respect to the interior component, wherein a backside of the substrate layer is free of obstructions; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

Abstract: An apparatus for stitching a component is provided. The apparatus includes an awl bar assembly coupled to a first drive device. The awl bar assembly is moved from a first position to a second position along the stitch path with an external drive device. A second drive device is coupled to the first drive device. A needle bar assembly is provided having a needle. The needle moves between an inserted and a withdrawn position, the needle bar assembly being pivotally coupled to the second drive device, the needle bar assembly moves from the first position to the second position with the same external drive device driving the awl bar assembly. A biasing member is coupled to the needle bar assembly, the biasing member being arranged to pivot and align the needle bar assembly in the second position in response to the needle bar being moved to the withdrawn position.