Automated Cutting Device for Pre-Shaped Bra Cups
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Solution Overview
Problem
The production of bras with pre-shaped cups is labor-intensive, prone to high margins of error, and lacks scalability due to the need for custom cutting devices for each style and size, leading to inefficiencies in the manufacturing process.
Innovation Solution
A method involving 3D digital patterns for a cutting device, utilizing a digital database with multiple patterns linked to bra sizes, and automated production processes using milling or 3D printing to create male and female parts, enabling precise and scalable manufacturing of pre-shaped cups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom cutting devices are created for each bra style and size, then the precision of cup production is improved, but the device complexity and labor intensity increase significantly
Solution Approach 1:
The patent applies universality by creating a single programmable cutting device that can produce multiple cup patterns through software control. Instead of manufacturing separate physical cutting devices for each bra style and size, the system uses a universal cutting device with a digital library of cup patterns that can be selected and executed programmatically, eliminating the need for custom hardware for each product variant
Solution Approach 2:
The patent implements copying by using digital 3D patterns and computer-aided design (CAD) models to represent cup geometries. These digital copies allow the cutting device to reproduce various cup shapes and sizes through software instructions rather than requiring physical prototypes or custom-built cutting tools for each design
2Adaptability or versatility
If manual cutting and finishing processes are used, then flexibility in handling different cup designs is maintained, but productivity decreases and error margins increase
Solution Approach 1:
The patent replaces manual mechanical cutting and finishing operations with automated computer-controlled cutting devices. The system uses digital patterns and programmable machinery to automatically cut cups according to specified designs, eliminating manual labor while maintaining design flexibility through software selection from a library of cup patterns
Solution Approach 2:
The patent applies parameter changes by using a digital database that stores various cup patterns with different geometric parameters. The system can quickly switch between different cup designs by loading different digital patterns and adjusting cutting parameters through software, enabling rapid adaptation to different designs without manual reconfiguration
3Manufacturing precision
If epoxy molds are used for cutting parts production, then dimensional consistency is improved, but the manufacturing time and labor intensity increase due to sanding and manual finishing
Solution Approach 1:
The patent replaces manual sanding and finishing operations with automated computer-controlled cutting devices that can achieve precise dimensions directly during the cutting process. The programmable cutting system eliminates the need for subsequent manual sanding by programming the cutting path to produce accurately dimensioned parts in one operation
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
Achieves a less labor-intensive, more efficient, and dimensionally consistent production of pre-shaped cups with reduced manual labor, allowing for faster and cost-effective manufacturing of bras with improved fit and reduced errors.
Implementation Method 1
The cup is then formed from a specific textile by means of a heat treatment
Data Source
Figure 1A
Figure 1B~2
Figure 3
AI summary
The present invention relates to a method for manufacturing a bra with pre-shaped cups, wherein the method comprises a production step of the pre-shaped cups, the cup production step comprising a step in which a textile suitable for this purpose is preformed into a cup in a mold, after which the resulting cup is cut out of the textile by means of a cutting device, the cutting device comprising a band saw and a male and female part between which the formed cup is clamped, the female and male part of the cutting device being variable and dependent on the cup size, and the female and male part being produced based on a 3D digital pattern of the male and female part of the cutting device.