I send my PDFs off to be printed, but I really like this idea. The main difference I might do if I go this route is projecting onto swedish tracing paper instead of directly onto the fabric. I just know my fabric would shift on me with my luck, but I could trace a projection.
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I don't sew. Just want to say this is brilliant.
After printing and taping together several patterns before cutting out, I basically stopped buying digital sewing patterns. Life is too short. I went back to printed commercial patterns. I have found the use of projectors for this really intriguing, but my sewing closet doesn't really have an easy/good place I can mount a projector to use. I can understand the appeal, though! I think that if I have to haul it out of storage every time, I'll just never use it.
How do you make sure it's not distorted, and also the right size? Seems like a nice use for a projector
To get the right size, it's a matter of selecting the right layer on the pdf. I usually have to make adjustments due to my waist-hip ratio and I use Inkscape to edit the files. A lot of indie pattern makers have started supporting projector friendly files. In terms of distortion, you always start with a calibration phase where you project a grid (usually in inches) and adjust pdf zoom & project settings (in case of skew) until the grid matches your physical measuring tool (mat, ruler,...). Then it's a matter of noting down the zoom percentage and opening any pattern pdf at that same percentage. These files often come with a small little grid on the side as well for a quick double check.