Variable-Diameter Circular Loom for On-Demand Woven Garments
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Solution Overview
Problem
The existing textile manufacturing processes, particularly for woven garments, result in significant waste due to the 'cut and sew' method, and are costly and time-consuming, with a need for on-demand production to eliminate waste and reduce production time and costs.
Innovation Solution
A system and method using a variable diameter circular loom that measures size parameters of a person and produces woven fabric products on demand by weaving clothing specifically tailored to fit the individual, utilizing body data from 3D scans or user-input metrics to create computer-readable instructions for the loom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cut and sew production methods are used, then garments can be manufactured using traditional processes, but significant fabric waste occurs and production time increases
Solution Approach 1:
The patent changes the fundamental parameter of production methodology from cut-and-sew to direct weaving. The loom is programmed to weave garments directly in the desired shape and size based on customer measurements, eliminating the cutting step that causes fabric waste. This parameter change transforms the manufacturing process from subtractive (cutting) to additive (weaving directly into final shape).
Solution Approach 2:
The patent extracts and eliminates the unnecessary cutting step from the traditional manufacturing process. By directly weaving garments to specification, the process removes the intermediate step of cutting fabric to shape, thereby eliminating the associated material waste while maintaining manufacturing capability.
2Adaptability or versatility
If multiple sizes of garments are produced in advance, then customer size requirements can be met, but inventory costs increase and unsold clothing may be discarded
Solution Approach 1:
The patent implements a made-to-order system where garments are produced only when a customer order is received. The automated loom system allows customers to specify their measurements and preferences, and the system automatically produces the custom garment without requiring pre-manufactured inventory. This self-service approach eliminates the need to maintain large inventories of multiple sizes.
Solution Approach 2:
The patent introduces dynamic, on-demand production capability that adapts to individual customer requirements. Rather than static pre-produced inventory, the system dynamically manufactures garments based on real-time customer orders and specifications, allowing unlimited size adaptability without corresponding inventory increases.
3Stability of the object's composition
If woven textiles are used instead of knitted textiles, then garment shape stability and thickness reduction are achieved, but seamless production becomes more difficult requiring multiple fabric pieces
Solution Approach 1:
The patent changes the loom's operational parameters to weave directly into three-dimensional garment shapes rather than producing flat fabric that requires cutting and assembly. The variable diameter circular loom adjusts its weaving parameters to create seamless garments in one continuous process, maintaining the shape stability benefits of woven textiles while eliminating the need for multiple fabric pieces.
4Manufacturing precision
If custom-fitted garments are produced for each customer, then perfect fit is achieved, but production time and manufacturing complexity increase
Solution Approach 1:
The patent replaces manual measurement and pattern-making processes with automated digital systems. Customer measurements are obtained through digital scanning or input, and the computer-controlled loom automatically translates these measurements into weaving instructions. This substitution of mechanical/manual processes with automated systems maintains high manufacturing precision for custom fit while reducing overall production time.
Solution Approach 2:
The patent performs preliminary digital modeling and pattern generation before actual weaving begins. The system calculates and prepares the weaving pattern based on customer measurements in advance, allowing the physical weaving process to proceed efficiently without delays during production. This preliminary computational action reduces the time required during the actual manufacturing phase.
Data Source
AI summary
An overall process of providing information needed for a circular loom to produce articles of clothing on demand is disclosed. Initially body data or measurements are generated for a person by scanning with a camera or other image capture device or estimated based on user-input body parameters. Measurements are extracted from the body data which are then processed with linear regression and other parameter extraction techniques. The extracted measurements are then processed. The resulting panel shapes are used to automatically produce the article of clothing as woven output with the loom.