Customized Apparel Manufacturing from Body Scan and Pattern Data
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Solution Overview
Problem
Conventional apparel manufacturing methods are inflexible, limiting design creativity and customization, with long process cycles and poor quality in post-production modifications, and do not allow for quick production of customized items.
Innovation Solution
A method and system that generate individual manufacturing data by combining body data and design preferences, using body scans and pattern data to create customized apparel, allowing real-time adjustments and production directly from these data, using machines like knitting machines for immediate production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional linear design process is used, then design is performed by manufacturer's designer, but design flexibility and customization capability are limited
Solution Approach 1:
The system enables end-users to independently create and customize their own apparel designs through an intuitive interface without requiring professional designer involvement. Users can directly manipulate 3D avatar models, select materials, and configure design parameters themselves, transforming the design process from a manufacturer-centric service to a user self-service model.
Solution Approach 2:
The patent replaces traditional manual design processes (sketching, pattern making, physical sampling) with a digital computer-based system. The mechanical interaction of physically manipulating fabric and patterns is substituted by digital manipulation of 3D models and virtual materials, enabling rapid iteration and customization without physical constraints.
2Reliability
If digital copy of garments is provided, then design can be stored and displayed, but design cannot be further modified
Solution Approach 1:
The system transitions from static digital garment copies to dynamic, editable 3D models. The design data structure allows real-time modification of parameters such as dimensions, patterns, colors, and materials while maintaining the underlying geometric integrity. This dynamic approach enables continuous adaptation of the design without losing the reliability of the base model.
Solution Approach 2:
The patent creates a parametric 3D model structure in advance that pre-defines editable parameters and constraints. This preliminary setup allows users to modify specific aspects of the design (such as sleeve length, collar type, or pattern placement) while the system automatically maintains consistency across related elements, enabling flexible modification without compromising overall design integrity.
3Adaptability or versatility
If t-shirt design machine with remote controllers is used, then user can virtually design t-shirt, but operation becomes too complex for ordinary user
Solution Approach 1:
The system uses a realistic 3D avatar that copies and represents the user's actual body measurements and proportions. This visual copy serves as an intuitive interface - users interact with the familiar visual representation of themselves rather than abstract parameters or complex controls, making the design process immediately understandable and easy to operate.
Solution Approach 2:
The patent employs visual and graphical interfaces where design modifications are represented through immediate visual feedback on the 3D avatar model. Changes in color, pattern, and material are displayed directly on the virtual garment, providing an intuitive visual language that eliminates the need for complex remote controllers or technical knowledge.
4Illumination intensity
If projection of design image on user is used, then design can be visualized, but interactivity is low and hands must be used for selection
Solution Approach 1:
The patent transitions from 2D projection displays to immersive 360-degree 3D visualization. The design is rendered as a three-dimensional virtual garment on a 3D avatar that can be viewed from all angles, providing spatial understanding and enhanced interactivity. Users can rotate, zoom, and manipulate the 3D model directly, creating a much more engaging and intuitive design experience compared to flat projections.
5Adaptability or versatility
If post-production modification with pens or screen printing is used, then design can be added to garment, but product quality becomes poor
Solution Approach 1:
The patent integrates design customization into the pre-production digital modeling phase rather than applying designs post-manufacturing. All design elements (patterns, colors, textures, embroidery) are programmed into the 3D model and manufacturing data before production begins, ensuring that designs are built-in with the same precision and quality as the garment itself, eliminating the quality degradation associated with post-production additions.
6Productivity
If conventional manufacturing methods are used, then production can be performed, but process cycle time becomes long and customized items cannot be produced
Solution Approach 1:
The system uses parametric modeling where all design attributes (dimensions, patterns, materials, colors) are defined as adjustable parameters in the digital model. Changing any parameter automatically updates the 3D visualization and generates new manufacturing data without requiring physical retooling or reconfiguration. This parametric approach enables rapid customization while maintaining high production speeds through automated data generation and direct manufacturing machine control.
Solution Approach 2:
The patent replaces traditional mechanical manufacturing workflows (physical pattern cutting, manual sampling, iterative prototyping) with automated digital processes. The 3D model directly generates manufacturing instructions for computer-controlled machines, eliminating the time-consuming mechanical steps and enabling immediate production of customized items without extending the process cycle.
Data Source
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AI summary
The present invention relates to a method and a system for the manufacture of a piece or apparel (1). According to an aspect of the invention, a method for the manufacture of a piece of apparel (1) comprises the steps of: (a) obtaining body data representative of at least one dimension of at least a part of the user's body, (b) obtaining pattern data representative of at least one pattern of the piece of apparel (1) to be manufactured, (c) generating based on the body data and the pattern data manufacturing data adapted to be processed by a manufacturing machine, and (d) sending the manufacturing data to a manufacturing machine for processing and for manufacturing at least a part of the piece of apparel.