When I saw Zach's outfit, this was my first thought as well. While it was the best designed and constructed, it was not the easiest to put into a pattern and duplicate. The red dress would give them multiple options to include in a pattern such as making it with short sleeves, no sleeves, shorter skirt, making it into a jumpsuit instead of a skirt, etc.
I also do not understand the judge's Samantha love. Last week I didn't get her muppet dress and all the praise when she used an "unconventional material" that was basically cloth. When compared to others making outfits out of floor mats, key chains, sun visors.... her choice to only use a fabric based material was not innovative or risky. This week, I felt like she was railroading her team to doing what she wanted to do by repeatedly talking about her great jacket and how it would be a show stopper. To me it was a basic concept that had no design element and was, frankly, poorly constructed. I'm not sure if her unfinished edges are a design choice, but it seems like in seasons past that would be critiqued for being unfinished or for not knowing how to do it.
It annoys me when they don't eliminate anyone because it seems clear that they would rather have cut someone from the winning team and are holding onto people who seriously underperformed. To me it was a no brainer that Matt should have went home, but they know he's good for sound bytes and personality so he's not going anywhere. It will be interesting to see next week if the 2 that go home were both on this week's winning team. My pure guess without having seen any spoilers or speculation is that it will be Jaxson and Victoria.