3D Contoured Garment Fabrication With Fiber-Solvent Bonding
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Solution Overview
Problem
The current garment-making process is inefficient and wasteful, contributing significantly to environmental impact due to labor-intensive steps and material waste, particularly in the cutting and sewing of cloth, which limits sustainability and customization options.
Innovation Solution
A method involving a fiber and solvent mixture is used with 3D printing or molding to create garments with three-dimensional contours, reducing the need for traditional steps like thread making and weaving, and allowing for local, on-demand production with customization capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional garment-making process (cutting and sewing cloth) is used, then garments can be produced, but significant material waste is generated
Solution Approach 1:
Instead of cutting shapes from cloth (subtractive method), the patent uses 3D printing to build garments directly from fiber and solvent mixture (additive method). This inversion of the manufacturing approach eliminates the need to cut away excess material, thereby reducing material waste while maintaining manufacturing capability
Solution Approach 2:
The patent changes the physical state and composition parameters by using a fiber and solvent mixture that can be extruded through a 3D printer. The solvent allows the fibers to flow and bond during printing, then evaporates or is removed afterward, transforming the material from a non-wearable state to a finished garment with minimal waste
2Productivity
If traditional garment-making process is used, then garments can be produced, but the process is labor-intensive and inefficient
Solution Approach 1:
The patent replaces manual cutting, sewing, and assembly operations with an automated 3D printing system. The 3D printer automatically extrudes the fiber-solvent mixture in predetermined patterns and uses heat or UV light to bond the fibers, eliminating the need for manual labor in these steps and significantly improving production efficiency
Solution Approach 2:
The patent combines multiple traditional manufacturing steps (fiber processing, yarn spinning, cloth weaving, cutting, and sewing) into a single 3D printing operation. By merging these separate processes into one additive manufacturing step, the system reduces manual labor requirements and improves overall productivity
3Loss of substance
If traditional cutting method is used to create garment shapes, then garments can be produced, but scrap materials are discarded
Solution Approach 1:
The patent uses digital design files to pre-program the exact garment shape and dimensions before manufacturing. The 3D printer follows these predetermined digital instructions to build the garment with precise contours, eliminating the need for physical pattern making and cutting, thereby preventing scrap material generation while maintaining manufacturing precision
4Adaptability or versatility
If traditional garment production is centralized, then economies of scale are achieved, but local customization and on-demand production are limited
Solution Approach 1:
The patent creates a universal 3D printing system that can produce various garment types and sizes using the same equipment and material mixture. The digital design files can be easily modified for different garment styles, sizes, and customizations, allowing the same system to serve both mass production and personalized on-demand manufacturing needs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a more eco-friendly and efficient process by minimizing waste, reducing manual labor costs, and enabling virtual fitting and local production of garments with precise specifications.
Implementation Method 1
a solvent capable to causing covalent bonds to be created between the fibers
Implementation Method 2
providing a catalyst to the fiber and solvent mixture in order to cause and/or control the rate of the formation of the covalent bonds between fibers. For example, heat is often a suitable catalyst
Implementation Method 3
providing heat as a catalyst to cause a plurality of bonds to form between the fibers in the fiber and solvent mixture
Implementation Method 4
aerating the aqueous suspension to generate a foam
Implementation Method 5
The foam is delivered to the mold and then dried and at least some of the liquid in the foam exits the mold through the at least one hole in the mold during the drying process
Data Source
AI summary
The present invention is directed to a method of making at least a portion of a garment that includes at least one three-dimensional contour. The disclosed method includes providing a fiber and solvent mixture that includes fibers and a solvent capable to causing a plurality of covalent bonds to be created between the fibers. In many embodiments, the plurality of covalent bonds form when a catalyst, such as heat, is provided to the fiber and solvent mixture. The process can be performed using, for example, either a 3D printer or mold form. The fibers used can be natural, synthetic, or a blend of natural and/or synthetic fibers. The solvent preferably includes ionic salts in water.