Tool for design and fabrication of knitted components

Abstract

To provide a computer-based systems for designing and manufacturing consumer products (for instance, knit footwear uppers, and the like).SOLUTION: The system provides digital controls for customization of knitted components (for instance, complex multi-structured knitted components). The system simulates deformations of knit structures and allows a user to control and visualize compensations in the structure(s) of the knitted component to better match between an intended knit design and an actual physical knitted component outcome. The system may manufacture / fabricate a knitted component based on the predicted / estimated deformation behavior of the knit.SELECTED DRAWING: Figure 3A

Description

[Technical Field]

[0001] This application claims the benefit of U.S. Provisional Application No. 62 / 685,701, entitled "Tool for Design and Fabrication of Knitted Components," filed June 15, 2018, the contents of which are incorporated by reference in their entirety.

[0002] FIELD OF THE INVENTION The technology disclosed herein relates to systems and methods used in the design of knitted components, and more particularly, the disclosed technology relates to methods and systems for the customization and manufacturing of knitted components and complex knitted structures. [Background technology]

[0003] Conventional athletic footwear includes two main elements: an upper and a sole structure. The upper provides coverage for the foot, thereby firmly receiving and positioning it against the sole structure. In addition, the upper may be configured to protect the foot and provide ventilation to cool the foot and remove sweat. The sole structure is secured to the underside of the upper and is positioned primarily between the foot and the ground. The sole structure may provide traction and control against potentially harmful foot movements (e.g., overpronation) in addition to attenuating ground reaction forces and absorbing energy (i.e., cushioning). Thus, the upper and sole structure work together to provide a comfortable structure suitable for a variety of walking activities (e.g., walking and running).

[0004] A variety of materials may be used in the manufacture of uppers and other knit or woven products (e.g., apparel articles and other wearable or non-wearable products). Some uppers are formed from knit materials (e.g., sewing and / or knitting yarns). Knit uppers have a different appearance than uppers formed from other materials, such as leather, synthetic leather, and rubber. During the design and manufacture of knit uppers, it is common for a designer to create the design and then for one or more others to program the knitting machine to manufacture the upper. Separating the design and manufacturing process can result in the development and manufacture of several uppers before the designer agrees on a design that can be produced by the knitting machine. Multiple production runs or cycles of numerous knit uppers that do not meet the designer's design vision can cost time and resources.

[0005] Furthermore, the use of digitally controlled tools for knit fabric customization can lead to production challenges, thereby limiting the reach of digital customization of knitted products on a mass scale. Importantly, this challenge is exacerbated when complex, multi-structure knits are involved. These challenges can arise, in part, due to physical changes in the overall dimensions of the knit / woven fabric when stitch structures with different physical attributes are combined within the same woven or knitted fabric component. For example, woven fabric contours are of particular importance because they are commonly pre-configured to specific shapes and dimensions (e.g., knitted footwear uppers) that must be repeatable. Conventional knit design processes and computational tools fail to support the simulation and prediction of these knit / woven fabric deformations. As a result, conventional processes for manufacturing / creating knitted components / products typically rely on the manual labor and knitting know-how of highly skilled individuals who manually perform repetitive testing to accurately create knitted components free of deformations and other manufacturing issues.

[0006] What is needed, then, is a knitting system and computational parameter tool that can be used in the digital design and industrial fabrication / manufacturing of knitted components / products, thereby providing a direct link between design and manufacturability. Such a link between design and manufacturability allows designers / users to accurately estimate fabric deformations and compensate and visualize fabric structures, thereby assisting them in the technical challenge of assigning knit structures to improve the match between the initial graphical intent of a knit design and the actual physical knit fabric results produced using a knitting machine. Such an approach can significantly improve the design to manufacturing process in knitting engineering and reduce the number of iteration cycles for knitting material samples, especially when knitting widely different designs, thereby enabling increased efficiency of knitting machines and knit production and reduced waste during the production process. Summary of the Invention

[0007] One or more of the above needs in the art are met by the presently disclosed systems and methods for designing wearable and non-wearable products (e.g., footwear uppers).

[0008] One or more embodiments of the present disclosure focus on the implementation of a digital customization system for knitted products. From a manufacturing perspective, the physical behavior of complex, multi-layered knitted components / fabrics presents a real challenge in achieving product individualization and customization on a mass scale. When making changes to a knitted component design, traditional knitting systems require a time-consuming iterative approach to production knitted component and / or fabric samples, followed by manual testing of these samples to determine / identify potential sample deformations. Deformations can be manifested by geometric changes in the sample. For example, a knitted portion of the sample may increase or decrease in length (in any direction). Furthermore, spatial deformations can indicate changes in the 3D morphology of the structure (e.g., an increase or decrease in the curvature of the knitted structure). Such deformations can be caused by a variety of factors (e.g., stitch structure, yarn properties, knitting density, among others). This iterative process is typically required for each change made to the knit design pattern. This inefficient process is time-consuming, wasteful, costly, and tedious, requiring the manual labor of trained knitting professionals to appropriately reprogram the knitting machine to perform each production task. This traditional process also prevents the adoption of more diverse manufacturing approaches, allowing designers or end users to gain improved flexibility in customizing their unique knit designs. Furthermore, the connection between the visual attributes (e.g., color, shade, density) of personalized knitted fabrics and their structural dynamics and how they interact with the human body has led to growing interest in improving the fit of knitted fabrics, thereby providing more customized and individually tailored products to end users. Thus, as explained further below, the improved and more accurate ability of knitting systems to predict knitted fabric behavior allows for increased personalization of the resulting knitted products.

[0009] The global textile and knitted product industry can greatly benefit from increased flexibility in production, precision, and speed. As noted above, from a product perspective, data reconstruction of files, if performed manually by knitting experts, can lead to information loss and nuanced changes in knitted components. In light of this, a system for digitally designing and fabricating knitted fabrics, as described hereinabove, increases efficiency in the knitted product creation / manufacturing process, thereby further improving the process. As described in further detail herein below, the knitting system implements physical simulations to estimate deformations of knitted components, thereby enabling designers (or end users) to dynamically add compensation and improve predictions about the final knitted results and physical output of the knitting machine.

[0010] The knitting system described herein requires the generation of a library of knit structures and the generation of comprehensive computational predictive models for compensation of deformations resulting from the combination of different aspect ratio structures within a knit component / fabric. Data associated with the library of knit structures may be obtained from separate sources and / or generated by the knitting system. The knitting system employs an extensive testing process of numerous knit samples and the maintenance / storage of the test results in a library (or other suitable data storage device) for later use. For example, each new knit sample or knit design tested by the knitting system may further include stitch combination analysis and measurements of physical knit behavior; this information may be stored in the library of knit structures and used to compare subsequent knit samples and the production of different knit designs. Thus, once data and parameters related to a new knit structure and its deformation behavior are obtained by the system, this information can be employed by the knitting system in subsequent testing and knit production, thereby increasing the automation and reliability of computational tools and knitting machines in the production of any knit design.

[0011] In some aspects of the present disclosure, the techniques of the present disclosure may be implemented in part or in whole in connection with a computer-readable medium, for example, by using storage of computer-executable instructions or modules, or computer-readable data structures. Of course, the methods and systems of the above-described embodiments may also include other additional elements, steps, computer-executable instructions, or computer-readable data structures.

[0012] The details of these and other embodiments of the disclosed technology are set forth in the accompanying drawings and the description that follows. Other features and advantages of the disclosed technology will be apparent from the description and drawings, and from the claims. [Brief explanation of the drawings]

[0013] The technology of the present disclosure is illustrated by way of example and not limitation in the accompanying drawings, in which like reference numerals indicate like elements and in which: [Figure 1] 1 illustrates a system for designing knitted components according to one or more aspects of the present disclosure. [Figure 2A] 1 illustrates exemplary face representations of various knit configurations, according to one or more aspects of the present disclosure. [Figure 2B] 1 illustrates an example of a manufactured knitted component according to one or more embodiments of the present disclosure. [Figure 3A] 1 illustrates an example workflow for designing and manufacturing a knitted component, according to one or more aspects of the present disclosure. [Figure 3B] 1 illustrates an example workflow for designing and manufacturing a knitted component, according to one or more aspects of the present disclosure. [Figure 3C] 1 illustrates further components of a system for designing knitted components, according to one or more embodiments of the present disclosure. [Figure 4A] 1 illustrates an example knit design for manufacturing a knitted component, according to one or more embodiments of the present disclosure. [Figure 4B] 1 illustrates an example knitted component made with different colored materials, according to one or more embodiments of the present disclosure. [Figure 5A] 1 illustrates an example matrix data structure and corresponding technical annotations and machine operations for the data structure, according to one or more aspects of the present disclosure. [Figure 5B] 1 illustrates an example matrix data structure and corresponding technical annotations and machine operations for the data structure, according to one or more aspects of the present disclosure. [Figure 5C] 10A-10C illustrate examples of modified knit structures for improved example knit designs, according to one or more aspects of the present disclosure. [Figure 5D] 10 illustrates an example of a spring-based simulation image, according to one or more aspects of the present disclosure. [Figure 5E] 1 illustrates an example knit structure of various knit components, according to one or more embodiments of the present disclosure. [Figure 6A] 10A-10C illustrate examples of different compensation methods for predicting the deformation behavior of a knitted component, according to one or more aspects of the present disclosure. [Figure 6B] 10A-10C illustrate examples of different compensation methods for predicting the deformation behavior of a knitted component, according to one or more aspects of the present disclosure. [Figure 6C] 10A-10C illustrate examples of different compensation methods for predicting the deformation behavior of a knitted component, according to one or more aspects of the present disclosure. [Figure 6D] 10A-10C illustrate examples of different compensation methods for predicting the deformation behavior of a knitted component, according to one or more aspects of the present disclosure. [Figure 6E] 10A-10C illustrate examples of different compensation methods for predicting the deformation behavior of a knitted component, according to one or more aspects of the present disclosure. [Figure 6F] 10A-10C illustrate examples of different compensation methods for predicting the deformation behavior of a knitted component, according to one or more aspects of the present disclosure. [Figure 7] 1 illustrates an example interface for designing knitted components, according to one or more aspects of the present disclosure. [Figure 8] 1 illustrates a method for designing a knitted component according to one or more aspects of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0014] Generally, as noted above, some aspects of the present disclosure relate to systems and methods for the design of consumer goods (e.g., products including knitted components and / or woven fabrics), as well as the simulation and evaluation of knitted designs and corresponding manufactured knitted components.

[0015] Interest in knitting has grown in recent years, resulting in a significant diversity of scales, materials, fabrication processes, and applications in textile technology. Innovations in textiles (e.g., knitting technologies) involve the creation of material assemblies that can accommodate substantial changes in conditions through their material and structural composition. Because textiles are used as flexible, strong, and lightweight media for composites, computing and predicting their behavior is of interest to manufacturers. In particular, as highly engineered materials, textiles and knitting can be customized to meet changing requirements and applications, achieving diverse performance characteristics. These diverse performance characteristics are useful to manufacturers in reducing the number of iterative (and expensive) trials that may be required to properly fabricate the intended knitted component with minimal fabric deformation based on the underlying product design.

[0016] Any desired type of design data (e.g., color of a portion of a product (e.g., a footwear article (e.g., various upper portions or elements) or an apparel article)) may be controllable, alterable, or customizable by a user of systems and methods according to aspects of the present disclosure. If desired, systems and methods according to at least some examples of the present disclosure may further enable a user to select various materials or other characteristics for various portions of the footwear article (e.g., different upper material(s); upper thickness(es); upper stiffness characteristics; arch support characteristics; impact attenuation characteristics; size, orientation, and / or location of openings or windows in the upper; pattern of openings provided in the upper; laser cut designs and / or characteristics; laser etched designs and / or characteristics, etc.).

[0017] Although described above in connection with the design of footwear articles, aspects of the present disclosure may also be used in the design of other consumer goods (e.g., apparel articles). In the footwear example, a user may be able to select various features of the footwear and manipulate a visual image of the footwear from a user interface or software application displayed on a display screen. The user interface may display one or more tools for modifying aspects or otherwise manipulating various design data of the footwear, as described herein.

[0018] Users may use computing devices to access design applications and / or websites. These computing devices establish communication channels within a network and communicate with a messaging server system (including one or more server computers) that provides interactive design features used to modify product designs. As described in further detail below, any desired communication link and communication protocol may be used to provide and control data exchange between the computing devices and the system. Users may use computing devices that connect to the online design system via a network (e.g., the Internet, a local area network (LAN), a wide area network (WAN), etc.). Users may connect their computing devices to the system via any communication channel (e.g., website portals and applications from various internal sites and / or external sites linking to manufacturer portals).

[0019] Many different types of computing devices may be used without departing from this disclosure (e.g., any computing device capable of establishing networked and / or peer-to-peer connections and providing the necessary display, user interface, and input capabilities, as described in more detail below). Some more specific examples of computing devices that may be used in systems and methods according to at least some examples of the present disclosure include, but are not limited to: desktop computers, personal computers, laptop computers, palmtop computers, handheld computers, mobile phones, any other mobile device or smartphone, personal digital assistants, computer workstations, televisions, etc.

[0020] Computing devices usable in systems and methods according to examples of the present disclosure include one or more input devices and a data processing system (e.g., including one or more microprocessors). Non-limiting examples of input devices that may be included with a computing device include traditional input devices (e.g., a keyboard (hard or soft); a mouse, trackball, rollerball, touchpad) or other pointing device; a stylus or other pen-based input device (e.g., for tablet PC-type computing devices); a disk drive; a USB port; a network connection; a joystick-type controller; a telephone connection; an Ethernet connection; voice recognition capabilities, etc. The computing device may also have "touch screen" capabilities, such that a user inputs data into the computing device by physically touching the display screen with the user's finger or a selection device (e.g., a stylus). Furthermore, any desired type of display device may be provided for use with the computing device of systems and methods according to aspects of the present disclosure (e.g., a display device integrated with the computing device itself, or a display device separate from but in communication with the computing device (e.g., a projector display, a separate monitor display)).

[0021] Exemplary Design and Manufacturing System 1 illustrates a system (e.g., system 100) for the design and manufacture of consumer goods (for example, but not limited to, knitted footwear uppers). System 100 may include a computing device (e.g., design computer 102, which may be programmed with software modules that perform various functions when executed by at least one processor). The software includes computer-executable instructions that may be stored on at least one tangible, non-transitory computer-readable medium (e.g., solid-state memory or magnetic memory).

[0022] The design computer 102 may be connected to a network (not shown) in any desired manner (e.g., conventional manner known and used in the art (e.g., using any conventional wired or wireless connection and any network connection protocol)) without departing from aspects of the present disclosure. Additionally or alternatively, the design computer 102 may be operatively in communication with one or more computing devices in a separate network (e.g., a network associated with a manufacturer or a network dedicated to one or more knitting machines for producing knitted components).

[0023] Systems and methods according to examples of the present disclosure also provide a user interface display on the user's computing device. This interface allows the user to review the contents of the design effort and to provide their own input to the design effort. The user interface is provided on a variety of devices and controlled by the user's computing device and / or a server system, and data for generating, maintaining, and receiving input through the user interface is generated and provided via computer-readable media included as part of or associated with the computing device and / or server system. Examples of such computer-readable media include, but are not limited to: computer-readable memory, including any type of computer-readable medium conventionally known and used in the computer industry, whether internal to the computer (e.g., a hard drive) or separate from the computer (e.g., a disk, a solid-state or flash memory device, data available via a network-type connection, etc.);

[0024] System 100 may include a variety of data structures (e.g., libraries storing information related to the design and manufacture of knitted components). For example, color library 111 may include a variety of color values. The individual color values ​​may be arranged in a database (e.g., a FileMaker Pro database). In one embodiment, the color values ​​have four channels (e.g., CMYK color values). In another embodiment, the color values ​​have three channels (e.g., RGB color values). The individual color values ​​may correspond to the colors of various materials (e.g., yarns) supplied to or available by the knitwear manufacturer. Heather library 118 may be connected to design computer 102 via the Internet. The heather library may include information about various heather patterns that can be produced by one or more knitting machines available to the knitwear manufacturer. Last library 112 may store information about lasts of various shapes and forms. The last library may also store data files corresponding to footwear designs. Grading library 113 may store information about a collection of previously graded uppers. This collection may identify product features (e.g., footwear (e.g., location of construction and other attributes, modifications made to grade a base design used with a range of shoe sizes)).

[0025] The knit structure library 117 may store information regarding various knit structures that can be used in the design and manufacture of knitted products. Different knit structures assembled in the design tool may be used to form the library 117. In some cases, the knit structure information may be obtained from one or more other computing devices or a suitable storage location (e.g., a product manufacturer's remote server). Additionally or alternatively, a user may access and store knitting information in the knit structure library. Thus, the library 117 may accumulate and store knit structure information and other data over time for each knit structure stored therein. As described in further detail below, the knitting system may be configured to generate a library of knit structures that can be used to improve the knitting process and the reliability and accuracy of creating / manufacturing complex knitted components / products, thereby reducing manufacturing issues and improving material utilization efficiency of the knitting machine, resulting in less material waste due to improved fit and performance of the resulting knitted products.

[0026] As noted above, in some cases, an initial dataset of knit structure information can be used to calibrate a knitting system (and / or knitting machine therein) to identify and differentiate between weave variations of knitted components. When each knitted structure has different structural and visual characteristics, linear and spatial variations occur when the different structures are combined. Linear variations can change the length of a knitted segment, while spatial variations can alter the natural curvature of a knitted segment and cause it to become non-planar. Complex distribution of knitted structures within a knitted component can result in significant variations from the knitted component's intended overall shape / frame. Therefore, to calibrate a knitting system, knitted components with different aspect ratios can be measured and employed in the knitting system (and / or its internal computational tools).

[0027] In some cases, this initial data set can be further calibrated by testing different variations of the knit design / pattern. For example, the knit design / pattern (or other image data) can be employed in a knitting system. There are many ways in which the knit design / pattern can be employed in a knitting system (e.g., by scanning or importing an image via a computing device and then transmitting / sending it to the knitting system, among others). Additionally or alternatively, the knit design / pattern can be employed in a knitting system by generating a parametric design internally, designing stitches with different stretch and visual characteristics via the knitting system, and / or assigning stitch patterns to specific regions or colors within the design to achieve different linear and spatial deformations in different regions. One or more of these knit designs may be based on variations of a three-color knitting technique. In one such technique, a "bird's eye" stitch is simultaneously knitted using three different yarns of different colors. Here, each region of the pattern can differ in both structure and yarn, doubling the possibilities for generating knit combinations. For the above example, such knit designs / patterns may have a positive / negative nature. One of the three different yarns can be advanced by the knitting machine to the forward side of the fabric forming a solid or mixed combination with either of the other two yarns. For example, the two knitted components shown in FIG. 2B are produced by the knitting machine and have the same knitting design and structure, but are knitted using alternating (yarn) colors. Thus, by generating knitted structures in an improved knitting system using information obtained from an initial data set and / or calibration tests, the number of knitted structures available to the knitting system for analysis in predicting fabric deformation can be increased. The knitting system allows for the assignment of yarn colors to design colors and stitch types, thereby increasing the number of available combinations available for producing / creating knitted structures via the knitting system.Additionally, knitting systems take into account knit design and knit structure deformations and other geometric information (e.g., stitch aspect ratios) when generating knit structures. Similarly, these improvements also enable knitting systems to introduce material / yarn color as another layer of information that can be used to predict knit deformations and improve other results.

[0028] As described in more detail with respect to Figures 3A and 4A, design websites, interfaces, and / or applications such as those described herein may display a variety of patterns or models available for custom design, e.g., as part of an interface display. These various different models of products (e.g., footwear, apparel, rugs, artwork) may include templates or "base" models from which a user can select as part of the design process. Such "base" models or templates may be added to or modified based on user selections during the design process.

[0029] 1 may communicate data to and from design computer 102 during a design session. For example, UI 115 may establish a communication channel with design computer 102 to provide a user interface for customizing or modifying a footwear design. The user interface may also be used to sample input data received from the design computer. The user interface may also be used to assign knit structures for a design. The user interface may receive information about knit structures from a library (e.g., library 117). The assignment logic (of user interface 115) for assigning knit structures to various designs may be controlled by the user, allowing flexibility in the design process. In some embodiments, user interface 115 may be executed and / or employed within design computer 102. Various types of software applications (including, but not limited to, the Rhinoceros 3D CAD software application (“Rhino”) and, for parametric design, the Grasshopper visual programming language and environment) may be executed in conjunction with or employed within user interface 115. Software for generating user interface 115 may reside on or on a computer-readable medium available to design computer 102 or knitting system 100. Alternatively, if desired, the software, or at least some portion(s) thereof, may reside on more than one computing device of knitting system 100. The knitting system may be operated and maintained by the same organization(s) or individual(s) that operates and maintains design computer 102, or may be operated, controlled, and maintained in whole or in part by a party separate from any or all of these entities.As some more detailed examples, the knitting system may be operated and maintained (and the user interface 115 may also be operated and maintained) by one or more entities (e.g., a manufacturer, a supplier selected by the manufacturer or retailer, etc.) whose products are manufactured through the knitting system and methods described below.

[0030] The construction rules component 120 may provide to the design computer 102 data regarding one or more construction rules associated with the physical and / or structural integrity required for a footwear upper (and / or other apparel article) to be produced and the corresponding base design. Construction rules specific to various types of products may be stored in the rules component 120, such as running footwear rules that provide structural integrity requirements and characteristics specific to running footwear. As described in further detail below, these construction rules may impose certain limitations on a user's ability to modify certain aspects of the footwear design during a design session in order to maintain the structural integrity of the footwear upper during manufacture and use by a wearer. In some embodiments of the present disclosure, the construction rules associated with the physical and / or structural integrity required for a footwear upper may vary depending on the type of footwear (e.g., running footwear, basketball footwear, football footwear) or the type of apparel or product.

[0031] Design computer 102 may include various modules that perform various operational functions of the design computer. For example, design computer 102 may include design module 103 that processes various design changes to the footwear design made via user interface 115. Design module 103 may also render images of the footwear design based on the processed design changes. Design computer 102 may include grading module 104 that processes and determines changes that may be applied to the footwear design based on grading changes (e.g., increasing or decreasing footwear size). For example, grading module 104 may extract information associated with a base footwear design and compare this information with data stored in grading library 113 to render new base designs for different footwear gradings. In some embodiments, grading module 104 may recommend one or more design changes to the base footwear design in light of the processed grading information. By calculating the difference between the desired 2D / 3D shape and the predicted shape as a function of size variation (gradation), the knitting system can use data indicative of these differences (e.g., comparison data) to suggest geometric design changes to compensate for the calculated differences. The knitting system can make such design change suggestions based on and in response to known linear and spatial variations of the particular stitch being used (e.g., one or more of the stitches described for FIG. 2A).

[0032] Design computer 102 may include a structural evaluation module 105 that processes data to determine the acceptability of design changes made to a footwear design via user interface 115. For example, structural evaluation module 105 may extract information associated with a base footwear design that has been modified to include one or more design changes and compare this information with data from construction rules component 120 to determine whether the intended design changes comply with predetermined construction rules and / or physical limitations associated with the base footwear design and / or knitting machine used to manufacture the footwear upper. This extracted information may include, for example, stitch elasticity and aspect ratio associated with the design. Such information may affect the final shape and performance of the resulting footwear. Additionally or alternatively, the extracted information may include knitting machine limitations that indicate different color or stitch thresholds applicable to specific areas of the design. In some embodiments of the present disclosure, evaluation module 105 may be in operative communication with a database (or other suitable form of storage device) that stores a plurality of predetermined structural integrity characteristics associated with a base footwear design, each available for selection by a user.

[0033] The design computer 102 may include a bill of materials module 106 to process data related to the availability of various materials that can be used to manufacture the knitted component 140 according to a product design (e.g., a footwear or apparel design). The design computer 102 may extract information related to the base design and compare this information with data regarding the current supply or availability of materials 130 to determine whether requested design changes are acceptable.

[0034] Design computer 102 may also include a time / cost estimation module 107 that processes data related to the cost of manufacturing knitted component 140 based on the footwear design. Design computer 102 may extract information related to the footwear design and compare this information with data collected by and / or stored in time / cost estimation module 107 to calculate the cost of manufacturing knitted component 140 (e.g., a footwear upper) based on the product design and determine whether this cost exceeds any pre-defined cost threshold. Time / cost estimation module 107 may recommend one or more design changes to the footwear design to reduce the estimated cost below the pre-defined cost threshold.

[0035] The design computer 102 may also use a time / cost estimation module 107 to process data related to the amount of time required to manufacture the knitted component 140 based on the product design. The design computer 102 may extract information related to the product design and compare this information with data collected by and / or stored in the time / cost estimation module 107 to calculate the amount of time required to manufacture the knitted component 140 based on the product design and determine whether this amount of time exceeds any predefined time threshold. The time / cost estimation module 107 may recommend one or more design changes to the product design to reduce the estimated manufacturing time to below the predefined time threshold. In some embodiments of the present disclosure, during a design session, an interface or sub-interface may be displayed to the user indicating the amount of time required to manufacture the knitted component given the current product design. As the user modifies the product design, the interface (or sub-interface) may be updated to reflect the updated amount of time required to manufacture the knitted component (e.g., a knitted footwear upper).

[0036] Design computer 102 may also use compilation module 108 to generate and / or output machine code and / or data files to a knitting machine (e.g., knitting machine 135). Design computer 102 (or other computing devices in knitting system 100) may use the compilation module to directly translate source code. For example, compilation module 108 may be configured to translate source code from a high-level programming language to a low-level language (e.g., machine code). This process may thus allow the knitting system, including user interface 115, to bypass the standard interface of the knitting machine. Design computer 102 may also use visualization / compensation module 110. Visualization / compensation module 110 obtains and analyzes information from (i) knit structure library 117 and knit structure pre-analysis / historical analysis, and / or (ii) output from a spring-based physics engine (e.g., engine 116) to assess differences between the knit design and the predicted fabrication results of the knitted component. The design computer 102 may also process input data and other information (e.g., data supplied by an end user or designer) using the input device 109. For example, via the input device 109, a user / designer may control the distribution of different stitch combinations within a knit component design and visualize selected / available knit structures / designs via a user interface (e.g., UI 115). The design computer 102 may also include various devices, interface units, and drives for reading and writing data or files. Exemplary interface units and drives include a keyboard, pointing device, microphone, pen device, touch screen, or other input device.

[0037] As noted above, some of the components shown in FIG. 1 may be interconnected via a network (e.g., a local area network (LAN) or a wide area network (WAN)). For example, color library 111 may be connected to design computer 102 via the Internet. In another example, design computer 102 may transmit knitting instructions in the form of one or more encrypted files to knitting machine 135 via a communications network (e.g., the Internet). The system shown in FIG. 1 may include conventional network components (not shown) (e.g., switches, wireless access points, and routers for connecting the illustrated components).

[0038] While depicted in FIG. 1 as a single knitting machine 135, knitting machine 135 may represent one or more knitting machines used to manufacture knitted component 140. These one or more knitting machines may be located in the same and / or different geographic locations. In some aspects of the present disclosure, the one or more knitting machines may be in operative communication with each other. Knitting machine 135 may include an industrial flatbed CNC knitting machine that is programmable and made for industrial manufacturing. Knitting machine 135 may further include two parallel rows of needles (referred to as a "needle bed") that include multiple needles used to continuously knit yarns or other materials fed into the machine. These yarns or other materials (e.g., material 130) may be fed into knitting machine 135 via multiple carriers. In some embodiments, the knitting machine may include sixteen (16) carriers. Complex knit structures can be produced via a knitting machine by electronically controlling specific needles that can transfer, skip, and / or cross knitting yarns between needles and across needle beds to produce knitted components based on the underlying knit design. Flat-bed knitting machines (e.g., knitting machine 135) can be configured to seamlessly fabricate three-dimensional volumes and operate at high volumes with little human intervention. However, when fabric deformations or other manufacturing issues occur compared to the intended design, modifications to the knitting design program / process may be necessary. Such modifications often require manual retrofitting by highly skilled operators, resulting in substantial reductions in knitting capacity and efficiency and increased product and associated overhead costs. For example, if the results of a knitting machine (e.g., a knitted component) are not as expected, knitting parameters may need to be changed or later identified by a technician to attempt to correct the problem. Knitting parameters that can be manually modified include, among other things, changes to the stitch density and / or structure of the knit itself (e.g., adding or subtracting stitches, rows, etc.). This hindsight approach to producing the desired knitted components and adjusting the knitting machine is time consuming and costly.According to the embodiments described herein, such adjustments and modifications are not necessary when all knitting parameters are calculated to optimize the shape and results of the knitted component, thus reducing the need to manually retrofit knitting machines when such production issues are encountered is desirable.

[0039] In one aspect of the present disclosure, the knitting system can be used to customize knitted products produced via an industrial flatbed knitting machine. For example, by employing a knitting machine at a retail location for in-store, on-demand customization, a user can create a specific design for a knitted component and have the knitted component manufactured based on this design. In some cases, these attempts at on-demand product customization of knitted components have been limited in scope and operability, so customization is primarily used within predefined and limited parameters (e.g., changing only the color of the knitting yarn) solely as a means to personalize the knitted component or product design. Other cases include adaptive modification of knitted components in limited and predefined ways. This more tailored form of knitted product “customization” can be supported by the knitting system, which aims to simplify the knitting interface and provide direct access to customization by end users.

[0040] 3A and other figures, in other aspects of the present disclosure, the present knitting systems, design tools, and knit component production encompass a broader definition of customization (e.g., providing a design environment configured to allow a user to substantially alter the combination of knit structures (e.g., size, shape, material composition), all within the same woven or knitted component). Computational knitting can greatly benefit from additional contributions, such as those described herein, that further develop and refine tools for digital knitting creation.

[0041] Additionally, different data sources can be generated and / or obtained by the knitting system to directly drive knit production and further serve as input for product specifications, improve production accuracy and efficiency, and reduce waste. This knitting process and information flow, described in more detail below with respect to FIG. 3A, can occur in real time. Such improved efficiency and communication along the design / production pipeline can lead to improved connectivity between stores and production facilities. Such improvements can also lead to improved communication and data flow between remote parties for knitting process enhancement. For example, data from online commerce activities, whether online shopping, customer engagement, or other feedback information (e.g., sensor data), can be obtained remotely. According to the knitting system described herein, the knitting process can be enhanced to predict deformations and other production issues in knitted fabric components, thereby enhancing the knitting process in a manner that provides on-demand mass production for a wide variety of knit designs and personalizations.

[0042] Within this environment for designing and manufacturing knitted components, in some aspects of the present disclosure, the systems described above may include one or more computing devices (e.g., design computer 102 (or internal computing tools)) that use multiple digital inputs in conjunction with a live parameter pipeline to generate the necessary machine code and output files to operate a knitting machine to manufacture a customized knit design. As described in further detail below with respect to at least FIG. 3A , knitting system 100, including one or more computing devices (e.g., design computer 102) therein, may be configured to (i) manufacture textiles including multiple knitted structures within the same sample or knitted component, (ii) interchange parameters of the knitted structures in a manner that does not change the overall geometry and dimensions of the textile profile, yet maintains the geometric proportions of the customized design within the sample or knitted component itself, and (iii) operate aspects of the knitting machine directly from the computing tools.

[0043] In further aspects of the present disclosure, various features of a user interface (e.g., user interface 115 and / or other suitable interfaces) for accepting user input and providing information about a knit design to a user are described in further detail below. Those skilled in the art will appreciate that the following description and accompanying drawings are merely illustrative of possible features, functions, interface component arrangements, interface component orientations, interface component combinations, etc. of systems, methods, and user interfaces according to one or more aspects of the present disclosure.

[0044] A further aspect of the present disclosure relates to a user interface provided on a computing device that allows a user to design an article of footwear (or other consumer product). The user interface may include elements and features that enable the use and / or activation of any of the features and / or functions described above and / or any of the features and / or functions described in further detail below.

[0045] As some more detailed examples, aspects of the disclosure relate to a computer-readable medium including computer-executable instructions for generating a user interface for a footwear design session on a computer-controlled display device, the computer-executable instructions stored on the computer-readable medium. The user interface may include, for example, (a) a first display portion including at least one rendering of the footwear article, (b) one or more selector elements (e.g., a pointer or cursor) that allow a first user to select portions of the footwear article, (c) indicators that show which portion(s) of the footwear article have been selected via the respective selector elements (e.g., text, icon, photo, animation), and (d) a first element that generates a change in the appearance of the rendering of the footwear article on the first display portion based on input generated by the first user. The first element (or at least some elements of the interface) may include features such as a color palette or color menu that allow a user to change the color of a selected portion of the footwear article and / or a component of the footwear article (e.g., a knit material); one or more orientation elements that allow a user to change the orientation of the footwear article as rendered in the first display; one-way, two-way, or multi-way user communication elements or features (e.g., text input and display panel(s), instant messaging capabilities, voice and / or video communication capabilities, etc.). The user interface may further include an input portion through which the first user can enter data used to set up a collaborative footwear design session with the second user (or another user).

[0046] With this general background and information in mind, more detailed information regarding exemplary embodiments of the systems, methods, computer-readable media, and user interfaces according to the present disclosure will now be described in greater detail. It should be understood that the following more detailed description relates to various specific examples of the present disclosure and its features and functionality, and that this description should not be construed as limiting the scope of the present disclosure.

[0047] I. Knitted Structure and Computational Design Tools Customization of knitted fabrics is inherently enabled through digital, machine, and material control of each stitch combination within the resulting knitted component / fabric. Compared to other textile techniques (e.g., weaving), knitting is often more adaptable due to the configuration of long, continuous yarns that form the woven or knitted component. In knitted fabrics / materials, these yarns can be internally looped through the knitting machine with individually controlled loop stitches. Changing the direction and tightness of the loops themselves and adjacent loops can affect the overall attributes and performance of the knitted component (e.g., its tensile properties, density, opacity, repeatability, fall, and other visual and physical properties). Additionally, during the knitting process, manufacturers can switch yarns to seamlessly integrate new materials into the knitted fabric / material.

[0048] Knitted fabrics are inherently flexible and stretchy, with nonlinear three-dimensional kinematics, a property resulting from the interlocking loops of continuous yarns that comprise the knitted fabric / material. As described in further detail below, aspects of the present disclosure relate to the digital innovation of industrially produced knitted fabrics (e.g., those comprising textiles / materials that may include complex or multiple knitting stitch combinations within the same knitted component / portion of a textile (which may be referred to as a "knitted structure"). Complex knitted structures can be achieved through the generation of a series of configurations. These configurations repeat themselves and impart an overall appearance and physical attributes to the textile.

[0049] 2 shows examples of different complex knit configurations that can be used to manufacture knitted components. In particular, FIG. 2A shows technical face designations of commonly used knit configurations (e.g., "plain knit" configuration 210; "rib" configuration 212; "transfer" configuration 214; "off or float" configuration 216; "over-sew" configuration 218; and "spread" configuration 220). For example, a variety of different knit structures can be generated using (and / or based on) a series of one or more repeating knit configurations (e.g., transfer and over-sew stitches). Information identifying one or more types of knit configurations / compositions associated with and / or available for the generation of a particular knit structure can be stored in library 117.

[0050] In some embodiments of the present disclosure, the knitting system 100 is informed by the knitting process and uses an inventive bottom-up approach based on an understanding of production-related requirements and processes for knitting materials and the operation of the knitting machine 135. In some embodiments of the present disclosure, one or more computing devices within the knitting system 100 (e.g., the design computer 102 (or computing tools therein)) may obtain and analyze multiple predefined knit structures (e.g., knit structure information stored in the library 117). The design computer 102 may further be used to combine one or more knit structures within the same woven or knitted fabric component. By strategically combining various knit structures in various permutations within the same knitted fabric component, the design computer 102 may analyze one or more of the typical proportion deviations, aspect ratios, and dimensions of each knitted fabric component from the intended knit shape or design. For example, if the stitch density of a knitted fabric structure is changed, the overall dimensions of a particular region of the knitted fabric component may change, but the ratio between width and length remains unaffected. Based on physical spring-based compensation analysis, available visualization tools (e.g., module 110) can be used to simulate the deformation of a knitted sample / component under static conditions. A knitted structure held at a specific size on a knitting machine can naturally be placed under tension due to the knitting process over time, even in the absence of external forces. When this knitted structure is removed from the knitting machine and placed at rest, it can change shape to accommodate minimum internal energy. This similarly describes the shrinkage phenomenon of any fiber (or even other material). That is, if placed at rest for a sufficient period of time without being forced into any shape, the knitted structure will eventually deform to its “natural” shape. Using multiple different modification tools, the design computer 102 or knitting system 100 can automatically redistribute forces within the knitted component / fabric in a manner that compensates for physical deformation, thereby enabling the production of knitted components that significantly resemble the intended knit design than would be possible using conventional knitting systems / processes.

[0051] FIG. 3A shows an example flow diagram of a method for designing and manufacturing a knitted component according to one or more embodiments of the present disclosure. The knitting process shown in FIG. 3A may also be referred to herein as a "computational tool pipeline." The stages shown in FIG. 3A may be performed by a system (e.g., knitting system 100 shown in FIG. 1). The process shown in FIG. 3A includes multiple stages (e.g., elements 302-308). Each of these stages may include one or more steps in the process of designing and manufacturing a knitted component as described herein.

[0052] For example, the first stage of the knitting process (or computational tool pipeline) may include an input stage (e.g., stage 302 shown in FIG. 3A). At this stage, knitting system 100 may obtain input (e.g., design input for the design of a knitted component). By way of example, as shown in FIG. 3B, element 332 shows an example image that may serve as input data for the knitting process and / or the intended knit design. In this example, the image shows an aerial photograph of sand dunes. A variety of other images, photographs, knit designs, and other information may be used by knitting system 100 as input data. Additionally, FIG. 3C shows additional elements of knitting system 100 that may be used to perform the various stages of the knitting process shown in FIG. 3A and described herein. For example, as shown in FIG. 3C, design computer 102 may receive and / or obtain input data / files 332 from one or more other computing devices or suitable data storage devices.

[0053] Knitting system 100 may use an input device (e.g., input device 109) or other suitable device to obtain input data. In some embodiments, the input device may include a parameter interchangeable input device shown in FIG. 3A as an image input (e.g., element 302). The input device may be configured to interface with a variety of data formats / structures (e.g., numeric vector and / or raster data formats).

[0054] A second stage of the knitting process (or computational tool pipeline) may include a sampling and assignment stage (e.g., stage 304 shown in FIG. 3A ). In this stage, knitting system 100 may sample input data (e.g., input data received in stage 302) using a visually flexible user interface (e.g., UI 115). The user interface may include assignment logic and / or obtain this assignment logic from one or more other computing devices (e.g., design computer 102, construction rules 120, etc.), thereby allowing a user flexible control over the design of the knitted component. For example, a user may use user interface 115 in selecting and / or assigning particular knit structures and / or knitting compositions that may comprise the overall knit design. Because different knit structures and / or knitting compositions may have different visual appearances when manufactured, using different knit structures in different portions of a component can cause the component to resemble a particular image provided as input data. Additionally, the overall knit design may include not only visual designs such as company logos, but also different stitches that may affect the physical performance of the knitted article / component. In some embodiments of the present disclosure, a computing device (e.g., design computer 102) within knitting system 100 may access library 117 (or any other suitable storage device) to obtain knit structures / compositions that can be utilized in designing a knitted component.

[0055] A third stage of the knitting process (or computational tool pipeline) may include a visualization and compensation stage (e.g., stage 304 shown in FIG. 3A ). In this stage, the knitting system 100 may evaluate, based on the assigned knit structure, a deformation between the design intent (e.g., the design of the knitted component prior to the assignment of the knitted structure) and the predicted / subsequent physical behavior of the knitted fabric after production by the knitting machine. This deformation is the spatial deformation of the knitted component relative to the design intent (i.e., the baseline geometry of the knitted component according to the original design prior to the assignment of any knitted structure for component formation). This deformation may relate to at least the peripheral profile (i.e., outer shape) of the knitted component. This deformation may relate to a mapping between the spatial distribution of the multiple portions of the knitted component according to the design intent and the predicted spatial distribution of the multiple portions of the knitted component based on the assigned knit structure. In some embodiments of the present disclosure, one or more computing devices in knitting system 100 may include a visualization and compensation module (e.g., module 110 of design computer 102) that uses information obtained from prior / historical analysis of the knit structure and / or output from a spring-based physics engine (e.g., engine 116) to assess such differences. As used herein, a spring-based physics engine refers to a computational model used in software that simulates one or more segments of a knit structure, design, or component as physical springs with predefined internal forces. This software tool is used to embed physical behavior in a 3D modeling environment, further enabling live interaction during simulation runtime. This software tool may be implemented on a computing device (e.g., spring engine 116 and / or computer 102) and may provide a variety of methods for generating forces affecting particles in the simulation and calculating force application for the spring model according to Hooke's Law of Elasticity through input measurements derived from a geometric model of the knitted component.

[0056] A fourth stage of the knitting process (or computational tool pipeline) may include a compilation stage (e.g., stage 306 shown in FIG. 3A). During this stage, one or more computing devices (e.g., design computer 102) of knitting system 100 may generate and / or output machine code and / or data files for operating a knitting machine (e.g., the knitting machine shown as element 310 in FIG. 3A or knitting machine 135 shown in FIG. 1). In some embodiments of the present disclosure, design computer 102 may include a compiler (e.g., compiler 108) that generates and / or outputs machine code and / or data files to knitting machine 135.

[0057] A. Evaluation and Fabrication of Knitted Components The geometric attributes of knitting (e.g., the ability of knitted components to adhere to certain complex, undevelopable, doubly curved geometries, the fact that knitted component manufacturing can be digitally conceived and applied with a myriad of materials and customized designs) partially explain why the development of improved design tools and manufacturing capabilities is desirable. Additionally, there is general interest in novel building materials and methods and processes for the manufacturing of knitted components (e.g., extensive efforts to integrate robotics, automation, and machine learning in fabrication and manufacturing processes). As such, embodiments of the present disclosure focus in part on the complex three-dimensional geometry of knitted components. This three-dimensional geometry is used to develop fiber-based building components for specific products that fit into product architecture and have distinct appearance and structural attributes, thereby providing users with enhanced customization opportunities. For example, a 2D knitted footwear upper can be fabricated and then used to fabricate a 3D footwear article employing the fabricated knitted footwear upper.

[0058] In addition to structural considerations related to product architecture, other forms of information input are considered to portray both visual and performance distinctions within the knitted structure of a knitted component. For example, in some embodiments of the present disclosure, data from multiple sensors (not shown) may be used by the knitting system 100 to record / determine changes in the knitting environment, which are rendered as variations in the knitted facade. For example, within the context of fiber-based structures produced using mold-less winding techniques, a continuous interchange of sensor information may be sent between a robotic effector and pneumatic formwork during the knit assembly process. For example, sensors on a knitting machine may measure the actual length of yarn knitted into a particular area of ​​the fabric. This data can be transferred to a design system and used as a feedback mechanism for improving the control and design of the knitted article. This communication of information may facilitate more predictable change and variation within the defining computational model or knit design. The examples and applications described herein illustrate the importance of generating direct feedback between the design domain and the actual creation of knitted components, and the potential of the information gathered to significantly transform manufacturing into more diverse and personalized systems.

[0059] While recent advances have made knit simulation somewhat more tractable and predictable, such achievements are often not a goal in manufacturing, focusing instead on the design of knitted components rather than their subsequent manufacturing or fabrication. The computational modeling of fiber behavior can be challenging due to the different logic and algorithms used to abstract the complex physical behavior of fibers. In particular, knitted fabrics are notoriously more difficult and distinct to model than woven fabrics, which offer a more general and simpler representation of fiber behavior.

[0060] In some embodiments of the present disclosure that distinguish between simple knits and more complex knits, the knitting system 100 (or one or more computing devices therein, e.g., design computer 102) can process different types of knitting stitches / compositions to determine the various orientations of the knitting yarns that comprise a knit design, test sample, or knitted fabric component, and how the individual paths of the knitting yarns affect the overall physical motion of the fabric. For example, use a generic mesh representation in a CAD (computer-aided design) environment, with specific stitch types assigned and various observed physical rest lengths assigned to each face. As a result, various more complex knitting patterns can be replicated and utilized in the knitting system for calibration and data collection purposes for jacquard weft knit lace fabrics, and spring-mass simulation can be implemented by the knitting system (e.g., spring engine 116) to derive stitch cycles that form a novel secondary grid for pattern simulation as a replacement for the generic fabric pattern.

[0061] In embodiments of the present disclosure, simulation models may be used to determine / predict the mechanical interactions between yarns or other materials at the crossings of the yarns at each stitch intersection of a knitted component. For example, computational models (e.g., neural networks and fuzzy logic models) may be used by one or more computing devices (e.g., design computer 102) of knitting system 100 to predict tactile properties related to the finishing of knitted fibers. Examples of such computational models include numerically characterizing complex concepts related to human sensory evaluation of fibers.

[0062] In some embodiments of the present disclosure, knitting system 100 may use one or more computational models to simulate and / or predict the physical behavior of knitted fabric components. For example, if a spring model provides a fast and reliable test / simulation method, the spring model may be used as a physics engine to implement the simulation, using particle modeling logic that is compatible with component-based modeling of knitted fabrics. The spring model used by knitting system 100 may be stored on and / or executed in spring engine 116.

[0063] As described in more detail below, knitting system 100 may be configured to embed information describing the physical behavior and properties of knitted fabric components directly into the 3D modeling environment, thereby enabling “live” (e.g., dynamic, real-time) interaction with the knit design as the simulation runs. In some embodiments, design computer 102 may be configured to perform such steps. For example, such steps may be performed by a computational tool (e.g., computational tool 333) of design computer 102. The knitting system may include various methods for generating forces that may affect portions of knitted fabric components within the simulation. In some embodiments, knitting system 100 may determine force application in a spring model using and based on the principles of Hooke's law of elasticity. Spring-based methods may also be used to simulate woven fabric behavior, thereby generating a modeling and simulation environment in a programmable language (e.g., Java) in conjunction with finite element analysis.

[0064] Finally, in other aspects of the present disclosure, one or more computing devices (e.g., design computer 102) of knitting system 100 may execute an application (or other software appropriate to the software / module, e.g., a compiler (e.g., compiler 108)) to bypass the standard interface of the knitting machine and directly translate source code from a high-level programming language to a low-level language (machine code). This bypass may be implemented when the knitting (or motion) task to be performed by the knitting machine cannot be accomplished by utilizing the normal / standard knitting machine interface. Such cases include, at least, when creating / manufacturing parametric knitting patterns (e.g., patterns based on generative, non-repetitive, large-scale geometric variations that cannot be designed and / or addressed through conventional knitting machine software).

[0065] In other aspects of the present disclosure, one or more compilers (or other suitable software / modules) of knitting system 100 may analyze and / or process complex three-dimensional geometries to shape a woven fabric into a particular configuration (e.g., a volumetric configuration). This may be accomplished, for example, by providing an automated knitting system that (i) forms volumes and controls their geometry, (ii) stitches the volumes together, and (iii) commands one or more knitting machines to build and / or manufacture knitted components. In yet other aspects of the present disclosure, knitting system 100 may use knitting machines (e.g., via design computer 102 sending knitting instructions to knitting machines 135) to knit complex, undevelopable surfaces into a single knitted component or woven article without the need for individual fitting or stitching. The knitting system 100 may use the design computer 102 (or computational tools therein) to (i) automatically sample a sample shape, knit composition, and / or knitted structure, (ii) cut the knitted structure into one or more knitting rows, and (iii) generate and / or create one or more knitting patterns.

[0066] In other aspects of the present disclosure, instead of utilizing machine logic to direct needle commands as a single continuous operation, knitting system 100 may use knit components or portions thereof (e.g., knit structure(s)) to derive a computational model. Specifically, the knitting system may use the knit structure repeat sequence(s) used by the knitting machine to create / generate new knitting structures and / or subsequent knitted components. In this manner, knitting system 100 may provide increased control and an improved, efficient level of predictability for implementing design decisions prior to knitted component production and for informing end users of available design options. By expanding the range of users, a foundation is provided for the creation of a common design environment for knitted components from design to production, and the present knitting system may reduce / alleviate the traditional reliance on technical experts to perform such tasks.

[0067] II. Further Examples of Knitted Component Evaluation and Fabrication In some embodiments of the present disclosure, the knitting system 100 may be configured to generate a knitted component using a knitting machine without utilizing the knitting machine's conventional / standard software interface(s). The design computer 102 may implement a computational tool (e.g., computational tool 333) that outputs two matching files. These files may, in some cases, be required by the knitting machine 135 to manufacture the knitted component. The first file may include detailed machine-level control language. In some cases, the first file may include a Sintral file and may be generated by a file generator (e.g., file generator 342) of the design computer 102. The second file may include a matrix array. In some embodiments of the present disclosure, the matrix array may include data indicating a knitting plan for the knitting machine. This matrix array may also include data (e.g., a Jacquard file) indicating and / or displaying the action and operation of each stitching needle. In some cases, the Jacquard file may be generated by a file generator (e.g., file generator 341) of the design computer 102.

[0068] In some embodiments of the present disclosure, one or more computing devices (e.g., design computer 102) of knitting system 100 may be configured to allow a designer or user to incorporate design changes within a predefined knitting region of a knitted component. Design computer 102 may also determine the shape and / or scale of the knitted component's outer shape to be produced and the graphic composition of the knitted component's contents. Furthermore, the knitting system may be configured to manufacture / create knitted components in a variety of shapes and patterns (e.g., the shape of a footwear upper or apparel article). In some embodiments of the present disclosure, the knitted component may include a rectangular shape. This rectangular shape may enhance the ease with which one or more computing devices (e.g., design computer 102) within knitting system 100 can evaluate variations from the original intent of the knitted design. Knitting system 100 may be configured to manufacture one or more knitted structures within the same knitted component, thereby enabling inherent two-dimensional (2D) complexity of the woven fabric due to the varying densities of various knitted structures that may coexist within the same knitted component. The importance of maintaining the shape of the fabricated knitted component(s) relates to the subsequent connection of a 2D layout pattern (e.g., a footwear upper) into a three-dimensional (3D) form (e.g., an article of footwear). In some embodiments, the connection of such a 2D layout pattern into a three-dimensional (3D) form can be achieved through stitching, which can be performed by a knitting machine 135 or other suitable stitching machine (not shown in FIG. 1 ). This serves to both illustrate and emphasize the importance of achieving highly accurate, repeatable dimensions of the knitted component. Furthermore, creating a 2D form that includes bends and folds, often used in the knitting process to achieve some volumetric shape before stitching, leads to a reliance on the knitting machine's ability to generate variations in the knitted structure. As such, the purpose of this disclosure relates to the creation of 3D shapes via a knitting machine.

[0069] In some embodiments of the present disclosure, an input device (e.g., input device 109) in the knitting system allows a user / designer to control the distribution of different stitch combinations within a knit component and physically knit or fabricate the knit component after visualizing the knit structure / pattern via a user interface (e.g., UI 115). Conventional design and / or visualization tools do not attempt to emulate the physical behavior of a knit fabric at rest. Similarly, under conventional design systems, combining different knit structures requires considerable know-how and technical expertise, especially when considering the performance behavior of different knit structures, taking into account stretch and deformation. As a result, conventional trials of "sketching" a knit fabric design pattern and predicting the behavior of the knit fabric prior to actual knitting / manufacturing have proven cumbersome, time-consuming, and inefficient, as this process typically requires repeated manufacturing trials using one or more knitting machines to produce a knit component with a physical appearance that accurately corresponds to the intended knit design. In fact, even with the involvement of experienced knitters and / or technical experts, the above-mentioned traditional "sketch" approach still requires multiple iterations to create a knitted component with the appropriate shape based on the complexity of the knitted structure / pattern and the stitch pattern of the knitted component to be produced by the knitting machine.

[0070] For example, the exemplary knitting design (e.g., knit design 402) shown in FIG. 4A may be used by knitting system 100 to create / manufacture knit components. Knit components 404 and 406, shown in FIG. 4B and described in further detail below, are variations in knit structures (stitches) assigned to each color in design 402, thus providing overall shape and deformation variations. In some cases, knit design 402 may initially be accepted without any knit structures, and individual knit structures may be assigned by the software according to a grayscale definition. That is, a grayscale representation of darker colored areas may indicate a more condensed knit structure, while lighter colored areas indicate a braided (or less dense) knit structure. This parameter can be controlled and changed by the user. Additionally, as described herein, the user may assign colors (e.g., yarn colors) to the knit design. The two knitted components shown in FIG. 4B (e.g., knitted components 404, 406) were produced using different knit structures on a knitting machine, resulting in different shapes of the woven fabric profile for each of knitted components 404 and 406. As shown in FIG. 4B, the knitted components also include different overall fabric dimensions from each other. In the example shown in FIG. 4B, both knitted component samples (e.g., elements 404, 406) were knitted using three identical yarns in three different colors on a knitting machine. Thus, at least in the example knit design 402 shown in FIG. 4B, this particular allocation of knit structures to the knit design slightly impacts the overall dimensions of the knitted component when different colored yarns / materials are used to manufacture the knitted component.

[0071] At least one objective of the present knitting system is to provide a mechanism for testing / evaluating the computational parameter production of knitted components / fabrics, focusing on the connectivity between design, design variations, knit structure assignment, and industrial manufacturing / production. In some embodiments of the present disclosure, the data output (e.g., machine code) of the design computer 102 maintains a live and / or real-time communication relationship between the knit design and instructions to the knitting machine, and also simultaneously updates any parameter variations in the knit design (or user interface) environment. This is in contrast to traditional knitting textile processes, which, as previously mentioned, require multiple manual digital translations by the various tradespeople, experts, or technicians involved in the industrial knitting process.

[0072] Another objective of the knitting system described herein is to enhance digital customization and / or user interfaces for operating knitting machines to improve the fit and / or performance of knitted products. In some embodiments of the present disclosure, when a uniform knitting pattern is used, parameter variations in the color distribution of materials (e.g., yarns) within the same knit / woven structure can be more easily achieved if the physical attributes of the knitted components (e.g., elasticity, material type, tensile strength, elongation, flexibility, durability, etc.) remain constant along with the primary knitting commands. In contrast, parameter distributions of knitted structures can change performance aspects of the knitted components and are also useful when designing knitted components for high-performance products (e.g., footwear and wearable apparel). Thus, instead of using traditional design / fabrication methods, altering the knitted structure of a knitted component may better address fit issues (e.g., improved grip, motion control and guidance, customized support, matching irregular / asymmetrical facial features, etc.).

[0073] A. A matrix data structure approach for knitting pattern generation In designing knitting patterns / structures, the knitting systems described herein may use input devices (e.g., input device 109) (e.g., parameter-interchangeable input devices capable of using multiple data type sources (e.g., numeric vector and / or raster-based data sources)). The use of a flexible design platform is conceptualized as multiple design inputs to instruct a knitting machine to create knitted components, and various types of data input sources (e.g., customer feedback data, sensor data, personalized body scans, etc.) may be employed. In some embodiments of the present disclosure, knitting system 100 may use grayscale images (and / or other types of images or input data) to present / predict possible parameter distributions of different knitted structures within the same woven or knitted fabric component. In some examples, grayscale images (and / or other input data used to generate a knitted fabric component) may be interchangeable. Additionally, user control options, which may be provided, for example, via UI 115 and / or design computer 102, may enable a user to control the knitted fabric structure distribution within a knitted fabric component.

[0074] As described above, in the input stage 302 of the exemplary knitting processor computational tool pipeline shown in FIG. 3A , the knitting system 100 obtains input data (e.g., input data / file 332) via input device 109. The knitting system 100, or one or more computational devices therein (e.g., design computer 102), may then process the input data to generate an output file (including a two-dimensional matrix array). In some embodiments of the present disclosure, the knitting system 100 may assign unique letters and / or identifiers to one or more rubrics in the matrix array. In some cases, each pixel of the design is assigned a unique letter / character after being defined as a dark, medium, or light color according to a scale threshold. Each unique letter / character is expanded into a compact array of characters corresponding to the array of commands used to form the matrix array. The rubric may include subdividing the initial knitting area into small squares, each of which is assigned a letter as a unique character associated with the knit structure. The user / designer may control the number of knitting structures and their distribution logic. For example, rubrics may be distributed according to an image or data file, and the user may select a filtering style for the image, which is essentially done by replacing color pixels with structural "rubrics" or components. These rubrics serve as a mechanism for assigning different stitch structures to regions in a knit design (e.g., knit design 402). This is accomplished by assigning colors in the knit design to the required rubrics. For example, this assignment may be made by (i) filtering pixel colors, (ii) using parametric equations, or (iii) manually assigning the required information according to the designer. In some cases, knitting system 100 may assign a unique letter and / or identifier to each rubric in the matrix array. The number of unique letters and / or identifiers assigned by knitting system 100 may correspond to the number of different knitting structures implemented for the manufacturing / creation of the knitted component.3B, element 334 illustrates an exemplary data structure (e.g., a matrix array) of unique characters that may be generated as output based on input data (e.g., element 332) and / or a knit design. The matrix data structure may be stored on the design computer 102, as illustrated by element 331 in FIG.

[0075] In some embodiments of the present disclosure, knitting system 100 may execute determination and / or assignment logic for distributing the different knit structures of a knit component relative to a particular data input or file (e.g., a raster image). This distribution performed by knitting system 100 may be achieved through sampling of grayscale tones and / or other input data. As described above with respect to FIG. 3A , knitting system 100 may perform such sampling during a sampling stage (e.g., stage 304) of a knitting process or computational tool pipeline via user interface 115. As an example, a 16-bit grayscale image contains over 260,000 tone values ​​between two predetermined values ​​(e.g., between zero (0) and one (1)). If a relatively small number of knit structures are used to design / create a knit component, knitting system 100 may apply a threshold mechanism for resampling the grayscale values ​​to a number consistent with the number of knit structures that a designer or end user desires to include in the knit component.

[0076] Knitting system 100 may assign one or more thresholds for the threshold mechanism, unique letters, and / or identifiers. In some cases, design computer 102 may assign a unique letter and / or identifier to each threshold. In some embodiments, when knitting system 100 evaluates a knitted component including a single yarn of one color, the knitting system may automatically arrange the knitted structures of the knitted component by density. For example, knitting system 100 may be configured to arrange the knitted structures from the densest and / or opaque structures to the least dense and / or braided structures. As such, the distribution of knitted structures may correspond to the grayscale tone levels of an image (or other input data) that may visually appear as a pixelated knitted component or woven fabric upon production by a knitting machine (e.g., knitting machine 135). In other aspects of the present disclosure, knitting system 100 may recommend or recommend to a designer or end user to arrange the knitted structures of the knitted component by density, for example, when the knitted component includes a single yarn of one color.

[0077] Referring again to the unique character matrix data array described above, knitting system 100 can automatically convert this matrix data structure into a standard, row-numbered Jacquard file format. For example, as shown in FIG. 3B , the matrix data structure (indicated by element 334) can be converted into a separate file format as indicated by element 336. In some cases, a computational tool (e.g., computational tool 334) executing on design computer 102 or other suitable computing device(s) of knitting system 100 can convert matrix data structure 331 into the Jacquard file format. In some cases, the conversion of the matrix data structure can be performed by file generator 341. The Jacquard file generated by knitting system 100 is comprised of an array of characters that represents a two-dimensional space containing one or more knitting commands for any particular knitting task to be performed by knitting machine 135. The strings in this array can be presented in sequential order of knitting machine 135 operation. This sequence of operations allows knitting to occur row by row and character by character from bottom to top as shown in the array shown in Figure 5A. Specifically, Figure 5A shows the needle command notation for an array of two knit structures (Structure A-element 510, and Structure B-element 520), illustrating one cycle of each structure. As further shown in Figure 5A, each character in the array defines an action / movement (e.g., knit configuration) to be performed by knitting machine 135, such as the various knit configurations shown in Figure 2. One or more needles of knitting machine 135 may perform various operations, such as: ● Sewing - the action of adding new yarn to a needle that previously held a loop or nothing; ● Knitting - the action of commanding the needle to draw a new yarn through the loop previously held by the needle, thus forming a new loop; • Disengagement or Float - An action that commands the needle not to act, allowing the new yarn to pass laterally without being drawn in. ● Transfer - the action of commanding a needle to move past the held loop(s) to an adjacent needle that is either empty or already holding a loop(s). For certain knitting machines, it may not be possible to feed a loop to a needle on the same needle bed, in which case a two-step action is required. ● Split - The action of combining a knit and transfer action into a single action. The split action commands the needle to knit through the loop onto the opposite needle bed without losing hold of the loop in the original knitting needle.

[0078] In some embodiments of the present disclosure, knitting machine commands / motions are doubled. Specifically, knitting system 100 may assign different unique letters to needles located on the front bed and / or the back bed of knitting machine 135. As such, a machine-level control file (e.g., a Sintral file) continuously obtains and evaluates information regarding matrix array positions and knitting commands from the Jacquard file.

[0079] FIG. 5B illustrates, via elements 512 and 522, technical annotations corresponding to the machine operations indicated by matrix data structure A (element 510) and matrix data structure B (element 520), respectively, shown in FIG. 5A. These annotations represent standard technical stitch annotations, with each symbol representing / representing a single knitting stitch performed by a particular knitting needle on a knitting machine. Such "illustrations" of knitted fabrics / components via technical annotations shown in FIG. 5B can be used to communicate specific knitted / woven fabric structures to a user and further to communicate such information when programming knitting machine 135 for execution of the intended creation / manufacturing of knitted fabric components. The drawings corresponding to elements 512 and 522 are simplified top views of two knitting beds (of knitting machine 135), with yarn lines indicating needle action / motion. Specifically, as noted above, the illustrations shown in FIG. 5B illustrate one cycle of each knitted fabric structure / pattern.

[0080] In producing a knitted component, knitting system 100 may rely on identifying knitted "block" structures rather than determining a single needle action. As such, in some embodiments of the present disclosure, knitting system 100 may assign a linear array of needle command actions for each repeating knitted structure in the final knitted component. This is particularly relevant when knitted structure(s) are repeated sequentially. Thus, knitting system 100 may be able to parse one or more unique characters of a matrix data structure with a compact array of needle command actions. For example, design computer 102, via (jacquard) file generator 341, may be able to parse each unique character of the matrix data structure with a compact array of needle command actions.

[0081] Knitting system 100 may analyze and break down a knit pattern / structure into its smallest repeating “blocks.” For example, as shown in FIG. 5C , element 532 shows an exemplary rendering of a repeating block of a portion of knit design 534. In this example, the knit design may already include corresponding stitch structure data. This data may originate, for example, from (i) an image and stitch assignments, or (ii) be generated directly by a parametric formula or a designer (user). One or more of these repeating blocks may consist of one or more needle actions. In some cases, each repeating block may consist of one or more needle actions. When different knit structures with different command action logic can be combined into a single output file, one or more matrix arrays may have different dimensions. Therefore, in such cases, knitting system 100 may use a common denominator for both the width and length of each knitting array, so that ultimately all combinations of knit structures (or corresponding command logic) may form a unified rectangular matrix at its boundary, thereby reducing and / or avoiding distortion of the knitting pattern.

[0082] In other aspects of the present disclosure, to improve the resolution of a particular / sample knit component, knitting system 100 may further decompose or "break down" the knit pattern beyond its individual visual components by (i) interrupting the cycle of the repeating pattern and (ii) adding smaller segments (or sub-blocks) of the original pattern to the knit structure. For example, as shown in FIG. 5C , further breakdown of the knit design of the knit component may be introduced by knitting system 100 across the width of the knit component, thereby altering the resolution and ratio of the image shown on the face of the knit component, resulting in a knit component (e.g., knit component 530) that includes a knit design with increased resolution. For example, with reference to FIG. 5C , element 532 shows an example of a repeating block that includes one or more knit structures for a portion of the original knit design (e.g., design 534). Element 532 includes multiple repeating cells and a single knit structure (e.g., element 535) comprised of a four-cell block of the knit pattern.

[0083] To improve the design resolution of the knitted components, as described above, one or more computing devices (e.g., consumer device 102) of knitting system 100 may analyze one or more portions of knit design 534 to decompose or break down knit structure 535 into smaller segments or sub-blocks, as shown by knit structures 537 and 539, which are comprised of two-cell blocks having a rectangular shape across their width. As can be seen from corresponding knit design 538 shown in FIG. 5C , the combination of decomposing the knitted structures in the original design and reassembling portions of the knitted structures to form new knitted structures allows the knitting system to improve the image / design resolution of the final knitted result (e.g., the knitted components (e.g., element 530) shown in FIG. 5C ). This "breakdown" or decomposition process of the knitted structure of the knitted component by knitting system 100, followed by reassembly of one or more portions of the knitted structure / composition with other fragments / portions of a different knitted structure / composition within the knitted component, allows knitting system 100 to generate a new knitted structure / composition based on the reassembly of different portions of the current knitted structure in the knitted component, thus generating both a new knitted structure and pattern within the knitted component. In other words, the knitting system considers knitting stitches that may or may not be placed relative to one another according to industry conventions to ensure there are no inconsistencies with the current design / composition. Furthermore, the knitting system reassembles stitches according to the designer / user and knitting "rules" or knitting machine limitations.

[0084] As described above, knitting system 100 may use a machine-level control file (Sintral) generator (e.g., file generator 342) to obtain (i) the final Jacquard file, (ii) the length and width dimensions of the initial canvas / woven / knitted components, (iii) unified structural dimensions (common denominator in both directions), and (iv) knitting machine parameters as inputs to the knitting machine. Knitting machine parameters may include various metrics associated with the knitting machine (e.g., overall machine width, fabric takedown, knitting and transfer speeds, and / or needle counters). These parameters and other machine information may be stored in one or more computing devices in the knitting system (e.g., design computer 102, as shown by element 343 in FIG. 3C). In some embodiments of the present disclosure, knitting system 100 stores this information as parameters in a specific location in a machine code file template (e.g., a Sintral file). The unconventional process of storing such parameters in machine code allows the end user or designer increased control over the operation of the knitting machine and dynamic changes to the knitting performed by the machine between iterations. The knitting machine 135 may use the output (e.g., a Sintral file) from the consumer design 102 for the production of the knitted component. This is shown in Figure 3B by elements 336 and 338.

[0085] B. Visualization and Simulation of Fabric Behavior As noted above, knit fabrics have unique properties, particularly due to the long, continuous, internally looped yarns, which can affect the overall behavior of the woven fabric. Due to these properties, knit components can have nonlinear 3D kinematics.

[0086] The simulation mechanism used by knitting system 100 takes as input the unique character dot matrix generated by the knitting system for visualization of the physical behavior of the knitted fabric components. Thus, if there may be specific quotients for each knit structure that differ from the expected square logic of the matrix array, knitting system 100 can convert each cell in the initial matrix to a specific rectangular measurement (as partially described above for rubric subdivisions). In some embodiments of the present disclosure, prior to simulation modeling, knitting system 100 can obtain data indicating knitted fabric sample dimensions. These dimensions are measured with the knitted fabric component or fabric in a relaxed state. Using this data, knitting system 100 can determine, for each knitted structure, a unique aspect ratio that is specific and constant for each knitted structure.

[0087] To simulate the internal forces that cause distortion of the knitted component, knitting system 100 can use mesh edges (in a mathematical representation (e.g., CAD) of the knitted component) to generate a grid of simulated springs that physically simulate these forces. There are multiple ways (e.g., CAD or general) for representing geometric information in software tools. As described herein, mesh edges (e.g., polygonal / pixel modeling) can be used to generate the grid because the conversion from mesh edges to spring calculations may require system-specific size information. This can be achieved through conversion to a mesh of Non-Uniform Rational B-Spline (NURB) surfaces (representing a general mathematical representation of a 3D object). Typically, when an object is scanned into a CAD program, it is first scanned using NURBS. Each length of each mesh edge is converted by knitting system 100 to a spring based on Hooke's law of elasticity. In some cases, this conversion can be performed by a computational device (e.g., spring engine 116) within knitting system 100. One or more computing devices (e.g., spring engine 116) of knitting system 100 may simulate springs as force objects, and the entire mesh may be used by knitting system 100 to enable visualization of the entire geometry of the knitted component. The output of this simulation may include the new geometry of the knitted component deformed by the springs, relative to the intended design of the component prior to the assignment of the knitted structure that may cause the deformation. In some embodiments of the present disclosure, knitting system 100 and / or one or more computing devices (e.g., spring engine 116) therein may generate dynamic, iterative simulations until the knitting system reaches equilibrium. FIG. 5D shows a still image from a spring-based simulation visualization of a knitted component (e.g., element 550) adjacent to an image of a fabricated knitted component (e.g., element 552). As shown in FIG. 5D, this exemplary test demonstrates a correlation between the simulated image 550 and the deformation behavior of knitted sample 552.

[0088] C. Compensation Methods for Knitted Component Design By integrating physical engine simulation with the knitting design and knitting production processes, knitting system 100 allows users to visualize the deformation behavior of a knitted component before the creation / manufacturing of the knitted component begins.

[0089] In some embodiments of the present disclosure, the knitting system 100 allows a user to control the overall shape of a woven or knitted fabric component by employing a first compensation method (e.g., a "row duplication" method). This first compensation method is based on differential row duplication and, in some cases, may be a preferred method for knitted fabric components that include knit structures with different heights. This compensation method involves selectively selecting regions of the knitted component and each knit structure where row duplication occurs to obtain extra length (e.g., in areas found to be "shorter" in the simulation process). The machine code (jacquard) generated by the knitting system 100 compensates for the height difference by strategically duplicating rows in the shorter knit structure. As described herein, the system generates the machine code as the final knitting instructions transmitted to one or more knitting machines. As a result, the knitting system 100 may knit different numbers of rows in different knitting regions in one continuous process. This row duplication method allows the knitting system (e.g., the design computer 102) to modify or alter one or more jacquard files. The Jacquard file may represent and / or contain a set of symbols used by the knitting machine to know what to knit on each needle in each row. As described herein, the knitting system may modify and initialize the Jacquard file according to a compensation method, and the system may generate a new Jacquard file based on the modifications.

[0090] In another aspect of the present disclosure, the knitting system 100 allows a designer or end user to control the outer shape of a knitted component by using a second compensation method (e.g., a “stitch density” method). This second compensation method is based on the automatic generation of a new information layer for dynamic control of the stitch density of the knitted component. This stitch density information layer information represents another generation of a bitmap of the knitted area with individual stitch density information for each stitch (needle action) in the design, similar to a Jacquard file but with stitch density information. In some cases, the knitting machine may include an optional specific extension of the Jacquard file to include stitch density information. By changing the stitch density of a knitted component that can be numerically controlled on the knitting machine, the knitting system can control whether the yarn loops generated by the knitting needles are fastened or released. The knitting system 100 may automatically fabricate this initial new layer of information by replicating the overall geometry of the knitted component and converting the information into stitch density values. As described above, in some cases, this new information layer may function as a component or extension of the Jacquard file. Thus, while a knitted fabric component may not change its pattern / design appearance / knit structure, the distribution of fastness within the knitted fabric component may change. As such, knitting system 100 may create individual stitch fastness mappings for each stitch in a pattern without changing the stitch structure and overall design. In some cases, knitting system 100 may alter the stitch density of a knitted fabric component only within selected regions of the knitted fabric component. Furthermore, knitting system 100 may store the stitch density changes of a knitted fabric component in an additional file, similar to a Jacquard file, which presents a new differential density matrix of values ​​that defines the stitch control of knitting machine 135.

[0091] The rest length of a knitted component may be automatically measured by the knitting system. In some cases, the rest length measurement may be performed manually. Additionally or alternatively, the manually measured rest length may be compared to the automatic measurement for calibration purposes of the automatic measurement. In some embodiments of the present disclosure, the rest length measurement may be used by the knitting system (e.g., UI 115 or spring engine 116) as a parameter defining the spring constant. For example, the system may determine the rest length measurement by sampling multiple knitted components at rest. The system may normalize these values ​​and store them in an appropriate memory area. Table 1 below shows an example list of rest length measurements for several different knitted structures (e.g., Structures 1-7) shown in FIG. 5E: [Table 1]

[0092] Evaluation of various compensation methods (e.g., the "row replication" method and the "stitch density" method) may be measured and scored by knitting system 100 using a mathematical model such as:

number

number

number

[0093] As shown above in equation (1), the first aspect ratio (“AR”) is determined by knitting system 100 measuring the initial area (“a”) of the initial knit design shape and multiplying this value by the maximum width (W maxAfter the knitting system 100 implements a compensation method (e.g., the "row replication" and "stitch density" methods (or a combination thereof) described above), the knitting system 100 calculates the second / updated aspect ratio of the design shape ("AR") using equation (2) by dividing the new area ("a") and new width ("W") of the knitted component. max Using equation (3), the knitting system may determine the quotient of the first aspect ratio and the second aspect ratio (i.e., the "ARR" score). This aspect ratio quotient between the design intent and the simulation (ARR) will tend to approach unity (1) to the extent that the two ratios are identical. The knitting system may also determine the area difference ("ADR" score) between the initial area ("a") and the new area ("a`"). In some cases, the knitting system may determine the ADR score based on the area of ​​deviation from the original knitting shape; the closer this ADR score is to zero (0), the more accurate the compensation.

[0094] These scores measured by the knitting system are used to shorten or reduce the trial-and-error iterative process used in conventional systems. However, these scores allow the knitting system to maintain a prototyping-based creative workflow during the development of new knitting prototypes. Upon scale-up, the knitting system remains relevant for end-user (as opposed to experienced designers and knitters) modifications of knitting properties.

[0095] Additionally or alternatively, the evaluation of compensation methods (e.g., “row replication” and “stitch density” methods) may be measured and scored by knitting system 100 using the following mathematical model:

number

number

[0096] Referring back to Equation 1, the total area (a) of the initial design shape is the square of the maximum width (Wmax) 2 ) to measure the geometric ratio (GAR). If the knitted component is square, the GAR value may be equal to (1). For other shapes, the GAR value may reflect the numerical ratio between the maximum width and the average length of the shape. After the knitting system implements the compensation strategy, the new area and width may be determined and compared to a template / sample knitted component (e.g., a knitted component with a perfect square shape). Further geometric deviation parameters can be determined by measuring the deviation of the deformed shape from the original shape (area difference ratio (ADR)). The original and deformed shapes are superimposed, and the absolute difference in area between the two is summed and normalized by the knitting system:

number

[0097] As shown in Equation 3 (above), dif(a-a') is the area difference for each of the original square edges, and A is the area of ​​the original square. Thus, an ADR score closer to zero (0) indicates that the shapes (e.g., the original shape and the shape of the knitted fabric design to which the compensation strategy has been applied) are more similar to each other, and therefore the compensation method is more accurate. The use of these scores allows for a shortened iterative trial-and-error process when developing new knitting prototypes, while maintaining a creative prototyping-based workflow and holistic approach to research and development.

[0098] 6A illustrates different compensation methods used by knitting system 100 to predict the deformation behavior of a knitted fabric component prior to production. For example, desired knit pattern 602 represents a particular knit design to be produced by knitting system 100. One or more computing devices (e.g., design computer 102) of knitting system 100 may determine evaluation scores (e.g., ADR score and ARR score) for one or more of the compensation methods performed according to knit pattern 602, as well as an evaluation score for the knit design without the compensation method applied. Additionally or alternatively, design computer 102 may determine an evaluation score for knit design 602 based on a combination of compensation methods.

[0099] As shown in FIG. 6A, element 604 shows a modified knit design visually illustrating the predicted deformation behavior of the knitted component before fabrication, and element 606 shows an image of the corresponding knitted component actually produced by a knitting machine based on the applied compensation method. This deformation is determined based on the assignment of specific knit structures to various portions of the knit pattern. The different knit structures assigned to each portion of the knit pattern result in each portion deforming to a different size upon removal from the knitting machine and after a certain relaxation period. For example, element 604A shows an image of the original knit design 602, including predicted deformation regions (indicated by red and yellow) and evaluation score values ​​(e.g., ADR and ARR) as determined by the knitting system without the application of the compensation method. As shown in FIGS. 6A-6E, the predicted deformation regions can be color-coded (e.g., red and yellow). In the illustrations shown in FIGS. 6A-6E, yellow can indicate areas in the original (intended) design that are not present during the simulation (i.e., shrinkage of the knitted component). Similarly, in these examples, red may indicate areas in the simulation that are not present in the intended design. Element 606A shows the resulting knitted component produced by the knitting machine, and as can be seen in FIG. 6A , the deformation behavior of the produced knitted component is consistent with the behavior predicted by the knitting system. As another example, element 604B shows an image of the original knit design 602, including predicted deformation areas (indicated in red and yellow) and evaluation score values ​​(e.g., ADR and ARR) as determined by the knitting system using the "row replication" compensation method. Element 606B shows the resulting knitted component produced by the knitting machine, and as can be seen in FIG. 6A , the deformation behavior of the produced knitted component is consistent with the behavior predicted by the knitting system.

[0100] Referring now to the example in FIG. 6D , element 605A shows an image of the original knit design 602, including predicted deformation areas (indicated in red and yellow) and evaluation score values ​​(e.g., ADR and GAR) as determined by the knitting system without applying the compensation method. Element 606A shows the resulting knitted component produced by the knitting machine, and as can be seen in FIG. 6D , the deformation behavior of the produced knitted component is consistent with the behavior predicted by the knitting system. As another example, element 605B shows an image of the original knit design 602, including predicted deformation areas (indicated in red and yellow) and evaluation score values ​​(e.g., ADR and GAR) as determined by the knitting system using the “row replication” compensation method. Element 606B shows the resulting knitted component produced by the knitting machine, and as can be seen in FIG. 6D , the deformation behavior of the produced knitted component is consistent with the behavior predicted by the knitting system.

[0101] As yet another example, as shown in FIG. 6A , element 604C shows an image of the original knit design 602, including predicted deformation areas (indicated in red and yellow) and evaluation score values ​​(e.g., ADR and ARR) as determined by the knitting system using the “stitch density” compensation method. Element 606C shows the resulting knitted component produced by the knitting machine using the above-described stitch density compensation, and as can be seen in FIG. 6A , the deformation behavior of the produced knitted component is consistent with the behavior predicted by the knitting system. As yet another example, element 604D shows an image of the original knit design 602, including predicted deformation areas (indicated in red and yellow) and evaluation score values ​​(e.g., ADR and ARR) as determined by the knitting system using a combination of the row replication method and the stitch density compensation method. Element 604D shows the resulting knitted component produced by the knitting machine, and as can be seen in FIG. 6A , the deformation behavior of the produced knitted component is consistent with the behavior predicted by the knitting system.

[0102] 6B and 6C show further examples of different compensation methods used by knitting system 100 to predict the deformation behavior of knitted components having different knit designs (eg, knit designs 612 and 622).

[0103] 6E and 6F show further examples of different compensation methods used by knitting system 100 to predict the deformation behavior of knitted components having different knit designs (eg, knit designs 612 and 622).

[0104] One or more computing devices of knitting system 100 may be configured to generate novel knit patterns. For example, consumer device 102 (or a computing tool (design tool 333) executing therein) may be configured to generate novel knit patterns. Knitting system 100 may generate known knit patterns by (i) identifying knit structures within a knit component (or knit design), (ii) "breaking down" these knit structures into smaller, repeatable assemblies, and (iii) recombining these fragmented pieces (or sub-blocks) to obtain novel, potentially unpredictable knit structures / patterns. This approach to generating novel knit structures / patterns is similar to the above-described process of refining or increasing the resolution of a knit design pattern by making it more responsive in terms of knit structure distribution and designability. Generating further methods for cutting / decomposing knitted structures into the smallest repeating patterns with the highest resolution using the knitting system 100 also involves the development of models for smooth transitions between different structures with different structural properties (e.g., transparency, density, and texture).

[0105] Importantly, a goal of the present knitting system is to enable engagement with end user(s) who can participate in the knit design process in a smooth and automated manner. In some embodiments of the present disclosure, knitting system 100 may use the generative pattern creation process described herein to generate knits derived from various types of input data (e.g., real-user-based data). For example, knitting system 100 may generate sensor-driven knitting information for the creation of knitted components. Other types of information (e.g., end-user-provided data reflecting end-user preferences and demands for higher performance) may also be used during the knitting process described above.

[0106] 7 shows an example interface for modifying a knit design according to one or more aspects of the present disclosure. User interface 700 includes a knitting machine image 735, a color reference palette 710, one or more color vectors (e.g., vector 715), a portion of the interface showing the knit structure (e.g., knit structure 720), and a display portion 701 showing a rendering of the knit design. User interface 700 may display animations illustrating various design choices and selections made by the user during the design process. As will be appreciated, the components of user interface 700 may include the same or similar features and functionality of corresponding components provided by user interface 115.

[0107] As another example, knit structure 720 may include the same or similar features and / or composition as the knit structures described herein. For example, although not shown in FIG. 7 , knit structure 720 may include (or display) information associated with the knit structure (e.g., the underlying knit composition or repeat blocks that comprise the knit structure). In some cases, a user may retrieve a color vector 715 in user interface 700 to associate (or assign) a particular color value (e.g., yarn / material color) to a particular knit structure. After retrieving or modifying the color vector, user interface 700 may graphically display the material (e.g., yarn from one or more spools associated with the selected color value) disposed in one or more portions of knitting machine image 735, as shown by element 736.

[0108] Knitting machine image 735 in user interface 700 may serve as a graphical representation of a knitting machine (e.g., knitting machine 135) used to produce a knitted product (e.g., a knit footwear upper). Materials (e.g., material 130 used by knitting machine 135 to produce knitted product 140) may be graphically represented in knitting machine image 735. For example, as shown by element 710, each color or color reference selected by the user may be graphically represented by one or more spools of knitting yarn (or some other material) in knitting machine image 735.

[0109] As the user selects and / or modifies various design choices, these selections may be reflected (e.g., graphically represented or simulated) in real time via knitting machine image 735 or other portions of interface 700. Changes to the color values ​​of color reference 710 may be reflected in knitting machine image 735, for example, by changing the color of one or more spools of yarn to correspond to the new color values. As another example, the number of colors available in a particular design may be graphically represented by the number of spools in knitting machine image 735. In this example, empty spools may indicate undefined or available color references that may be added to a color palette.

[0110] As will be appreciated, a user's design choices may be limited based on constraints associated with knit design (e.g., material availability, construction rules, and physical limitations of the knitting machine). For example, due to limited supplies of certain materials used in manufacturing knit products, a user may be limited in the number of color choices corresponding to the availability or supply of these materials (e.g., knitting yarns). Thus, if a user selects color criteria 711, the user may be presented with a list of color options corresponding to the currently supplied materials. As another example, due to the construction or physical limitations of the knitting machine, a user may be limited in the number of color options that can be assigned to a particular knit structure. For example, if a knitting machine (e.g., knitting machine 135) has a predetermined number of "feeders," a user may be limited in the number of color combinations or colors that can be assigned to a knit structure based on the number of feeders in the knitting machine.

[0111] 8 illustrates a method for designing and manufacturing a knitted component according to one or more embodiments of the present disclosure. The steps illustrated in FIG. 8 may be performed by a system (e.g., knitting system 100 shown in FIG. 1).

[0112] Initially, in step 802, the knitting system obtains knit structure information. The system may obtain the knit structure information from one or more computing devices and / or a suitable storage area (e.g., library 117). Additionally or alternatively, the knitting system may obtain some (or all) of the knit structure information through analysis of one or more knit samples / components.

[0113] In step 804, the knitting system obtains design input data. The system may use this design input data to manufacture a knitted component having a graphic design corresponding to an image associated with the obtained design input data. The input data may include a data file (e.g., a raster image). The input data may specify various visual and physical attributes (e.g., features) associated with the knit design. In some embodiments, a user may select a knit design from multiple knit designs stored by the system.

[0114] Next, in step 806, the knitting system samples the design input data (e.g., the input data obtained during step 804). The knitting system may use a user interface (e.g., UI 115) to sample the input data. The user interface may include and / or obtain from one or more other computing devices of the knitting system assignment logic, which allows the user flexible control over the design of the knitted component, and in step 808, the knitting system may assign knit structures for the knitted component to be produced. In step 808, the knitting system assigns knit structures using input provided by the end user / designer. In some embodiments, the system may distribute different knit structures for the knitted component in relation to a particular data input or file (e.g., the input data obtained during step 804). The distribution of knit structures may be based on the sampling of grayscale tones and / or other input data in step 806.

[0115] In step 810, the knitting system evaluates the difference between the knit design and the predicted / determined knitted components. As described herein, the system may implement a physical simulation of the estimated deformation of the knitted components, allowing the system to dynamically add compensation based on different methods to achieve improved predictions about the final knitting result and physical output of the knitting machine (e.g., a prediction where the output profile more closely resembles the profile according to the original knitted design compared to the intended design). The knitting system may evaluate the difference between the knit design and the predicted / determined knitted components based on the assigned knit structure. In step 810, the system may simulate the deformation of the knitted components under static conditions based on a physical spring-based compensation analysis. The knitting system may automatically determine the redistribution forces in the knitted components / fabric to compensate for the physical deformation. The knitting system may include a dynamic system that simulates forces between elements and deforms these elements accordingly. After calculating the initial deformation, further calculations may be performed to determine a new deformation until equilibrium is achieved. In step 810, the system may evaluate the determined differences using one or more evaluation scores.

[0116] In step 812, the knitting system generates and / or outputs machine code and / or data files for operating the knitting machine. In some embodiments of the present disclosure, the knitting system may include a compiler (e.g., compiler 108) that generates and / or outputs machine code and / or data files to the knitting machine 135.

[0117] In step 812, the system may use a file generator (e.g., file generator 342) to generate a data file (e.g., a Sintral file) for controlling the knitting machine. The knitting system may generate the data file based on various inputs (e.g., a Jacquard file, length and width dimensions of the initial knitted component, uniform structure dimensions, and knitting machine parameters). In step 814, the knitting system may manufacture or produce the knitted component. One or more knitting machines of the knitting system may manufacture / produce the knitted component based on the instructions or machine code output generated in step 812.

[0118] While the present disclosure has been described in terms of specific examples, including presently preferred modes of carrying out aspects of the disclosure, those skilled in the art will recognize that numerous modifications and substitutions of the above-described systems and techniques are possible without departing from the present disclosure. For example, the systems, methods, and / or user interfaces may include more, fewer, and / or different functions than those described above, and various features of the systems, methods, and / or user interfaces may be activated or interact in a variety of different ways (e.g., using different types of interface elements) than those described above. Also, various process steps may be changed, reordered, omitted, and / or include additional steps or features without departing from the present disclosure. Various changes and modifications in the systems, methods, and user interfaces may be made without departing from the spirit and scope of the present disclosure, as set forth in the appended claims.

[0119] Various features are highlighted hereinafter in a set of numbered sections or paragraphs. These features should not be construed as limiting the invention or inventive concepts, but are provided merely as highlighting some of the features described herein, and do not imply any particular order of importance or relevance of such features.

[0120] Item 1: A method comprising: obtaining, by a computing device, a first set of knit structure information; obtaining, by the computing device, design input data; assigning one or more knitted structures to a knit design based on the design input data and the knit structure information; generating, by the computing device, one or more output files indicating a plurality of knitting instructions based on the knit design; and transmitting the one or more output files to a knitting machine for production of a knitted component.

[0121] Item 2: The method of item 1, wherein the design input data includes a raster image.

[0122] Item 3: The method of items 1 or 2, wherein the design input data includes at least one of a set of visual attributes and a set of physical attributes associated with the knit design.

[0123] Item 4: The method of any one of items 1 to 3, further comprising sampling, by the computing device, a plurality of grayscale images associated with the design input data.

[0124] Item 5: The method of any one of items 1 to 4, wherein the assignment of the one or more knit structures to the knit design is based on grayscale tone levels associated with the design input data.

[0125] Clause 6: A method according to any one of clauses 1 to 5, wherein assigning the one or more knitting structures further includes receiving a user input selection for assigning the one or more knitting structures via a user interface.

[0126] Item 7: The method of any one of items 1 to 6, further comprising determining, by the computing device, a deformation of the knitted fabric component corresponding to the knit design based on the intended knit design.

[0127] Clause 8: The method of clause 7, further comprising: displaying the deformation of the knitted component by the computing device; determining, by the computing device, a plurality of predicted compensation results corresponding to the knit design based on one or more compensation routines; and applying one or more redistributed forces in the knitted component based on the predicted compensation results to compensate for the determined deformation.

[0128] Item 9: The method of any one of items 1 to 8, further comprising generating, by the computing device, a matrix data structure indicating a plurality of knitting instructions for a knitting machine based on the knit design.

[0129] Item 10: A non-transitory machine-readable medium storing instructions that, when executed, cause a computing device to obtain a first set of knit structure information, obtain design input data, assign one or more knitted structures to a knit design based on the design input data and the knit structure information, generate one or more output files based on the knit design, the output files indicating a plurality of knitting instructions, and transmit the one or more output files to a knitting machine for production of a knitted component.

[0130] Clause 11: The non-transitory machine-readable medium of clause 11, wherein the design input data includes a raster image.

[0131] Item 12: The non-transitory machine-readable medium of items 10 or 11, wherein the design input data includes at least one of a set of visual attributes or a set of physical attributes associated with the knit design.

[0132] Item 13: A non-transitory machine-readable medium described in any one of items 10 to 12, wherein the assignment of the one or more knitted structures in the knit design corresponds to a grayscale tone level associated with the design input data.

[0133] Item 14: A non-transitory machine-readable medium described in any one of Items 10 to 13, wherein, when the instructions are executed, the instructions further cause the computing device to determine a deformation of the knitted component corresponding to the knit design.

[0134] Item 15: The non-transitory machine-readable medium of Item 14, wherein when the instructions are executed, the instructions further cause the computing device to: display deformation of the knitted component; determine a plurality of predicted compensation results corresponding to the knit design based on one or more compensation routines; and apply one or more redistribution forces in the knitted component based on the predicted compensation results to compensate for the determined deformation.

[0135] Item 16: A non-transitory machine-readable medium described in any one of Items 10 to 15, wherein when the instructions are executed, the instructions further cause the computing device to generate a matrix data structure indicating a plurality of knitting instructions for a knitting machine based on the knit design.

[0136] Item 17: An apparatus including one or more processors and a memory storing instructions that, when executed, cause the apparatus to obtain a first set of knit structure information; obtain design input data; assign one or more knitted structures to a knit design based on the design input data and the knit structure information; generate one or more output files based on the knit design, the output files indicating a plurality of knitting instructions; and transmit the one or more output files to a knitting machine for production of a knitted component.

[0137] Item 18: The device described in Item 17, wherein the instructions, when executed, further cause the device to determine a deformation of the knitted fabric component corresponding to the knit design.

[0138] Item 19: The device described in Item 18, wherein when the instructions are executed, the instructions further cause the device to display the deformation of the knitted component, determine a plurality of predicted compensation results corresponding to the knit design based on the one or more compensation routines, and apply one or more redistributed forces in the knitted component to compensate for the determined deformation based on the predicted compensation results.

[0139] Item 20: An apparatus described in any one of items 17 to 19, wherein when the instructions are executed, the instructions further cause the apparatus to generate a matrix data structure indicating a plurality of knitting instructions for a knitting machine based on the knit design.

Claims

1. modifying, with a computing device, a knit design including one or more first knit structures to compensate for expected deformation associated with the knit design by increasing a length of at least a portion of the one or more first knit structures, the modifying including replicating one or more knitting rows associated with the one or more first knit structures of the knit design, each of the knitting rows indicating a plurality of needle commands for producing the knitting row; sending knitting instructions associated with the modified knit design to a knitting machine.

2. receiving, by the computing device, design input data including at least one of a set of visual attributes and a set of physical attributes associated with the knit design; The method of claim 1.

3. the at least a portion of the one or more first knit structures includes an area of ​​the knit design determined to be shorter than a corresponding area of ​​an intended knit design; The method of claim 1.

4. increasing the length of at least a portion of the one or more first knit structures based on an amount of deviation between the knit design and an intended knit design; the method further includes using a physical engine simulation to determine the amount of deviation between the knit design and the intended knit design. The method of claim 1.

5. generating, by the computing device, a data structure indicative of the knitting instructions for the knitting machine; populating the data structure with a plurality of rubrics associated with the one or more first knitting structures; The method of claim 4 further comprising:

6. Modifying the knit design includes: determining a plurality of predicted compensation results corresponding to the knit design based on one or more compensation routines; determining a compensation routine of the one or more compensation routines to compensate for the deformation based on scores associated with the plurality of predicted compensation results; The method of claim 1 further comprising:

7. determining a first aspect ratio associated with the one or more first knit structures; determining one or more second knit structures by one or more compensation routines; determining a score for the one or more first knitted structures based on a comparison of the first aspect ratio and a second aspect ratio, the second aspect ratio being associated with the one or more second knitted structures; The method of claim 1 further comprising:

8. determining a compensation routine of the one or more compensation routines for the knit design based on the score associated with the one or more first knit structures. The method of claim 7.

9. the modifying further includes adjusting a stitch density associated with the one or more first knit structures of the knit design. The method of claim 1.

10. A non-transitory machine-readable medium storing instructions that, when executed, cause a computing device to: modifying a knit design including one or more first knit structures to compensate for expected deformation associated with the knit design by increasing a length of at least a portion of the one or more first knit structures, the modifying including replicating one or more knitting rows associated with the one or more first knit structures of the knit design, each of the knitting rows indicating a plurality of needle commands for producing the knitting row; causing a knitting machine to transmit knitting instructions associated with said modified knit design; Non-transitory machine-readable media.

11. The instructions, when executed, further cause the computing device to: The non-transitory machine-readable medium of claim 10 , wherein design input data is received, the design input data including at least one of a set of visual attributes and a set of physical attributes associated with the knit design.

12. The instructions, when executed, further cause the computing device to: The non-transitory machine-readable medium of claim 10 , causing a distribution of the one or more first knit structures of the knit design to be determined.

13. The instructions, when executed, further cause the computing device to: generating a data structure indicative of the knitting instructions for the knitting machine; and distributing, into the data structure, a plurality of rubrics associated with the one or more first knitting structures; The non-transitory machine-readable medium of claim 12 , wherein the distribution of the one or more first knit structures is determined by:

14. The instructions, when executed, further cause the computing device to: determining a plurality of predicted compensation results corresponding to the knit design based on one or more compensation routines; and determining a compensation routine of the one or more compensation routines to compensate for the deformation based on scores associated with the plurality of predicted compensation results; The non-transitory machine-readable medium of claim 10 , wherein the knit design is altered by

15. The instructions, when executed, further cause the computing device to: adjusting a stitch density associated with the one or more first knit structures of the knit design; The non-transitory machine-readable medium of claim 10 , wherein the knit design is altered by

16. 1. An apparatus comprising: one or more processors; and a memory storing instructions that, when executed, cause the device to: modifying a knit design including one or more first knit structures to compensate for expected deformation associated with the knit design by increasing a length of at least a portion of the one or more first knit structures, the modifying including replicating one or more knitting rows associated with the one or more first knit structures of the knit design, each of the knitting rows indicating a plurality of needle commands for producing the knitting row; causing a knitting machine to transmit knitting instructions associated with said modified knit design; Device.

17. The instructions, when executed, further cause the device to: determining a distribution of the one or more first knit structures of the knit design; 17. The apparatus of claim 16.

18. the at least a portion of the one or more first knit structures includes an area of ​​the knit design determined to be shorter than a corresponding area of ​​an intended knit design; 18. The apparatus of claim 17.

19. The instructions, when executed, further cause the device to: receiving design input data including at least one of a set of visual attributes and a set of physical attributes associated with the knit design; 17. The apparatus of claim 16.

20. The instructions, when executed, further cause the device to: adjusting a stitch density associated with the one or more first knit structures of the knit design; 17. The apparatus of claim 16, wherein the knit design is altered by:

Images