Custom-Fit Knitted Articles Using Digital Body Representations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional knitted textile manufacturing methods produce garments and articles in standardized sizes, leading to inconsistent fits across different manufacturers, as consumers cannot be assured of a reasonable fit due to varying size standards, and this issue is exacerbated for non-garment articles lacking standardized sizes.
Innovation Solution
A process involving the collection of custom-fit information through digital representations, such as scans or images, which are then processed to generate customized stitch counts and patterns for computerized knitting machines, allowing for the creation of tailored knitted articles that accurately fit individual specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standardized sizes are used for mass production, then productivity is improved, but manufacturing precision deteriorates due to inconsistent fits across different manufacturers
Solution Approach 1:
The patent changes the sizing parameters from standardized fixed dimensions to customized dimensions based on individual body measurements. The system captures body scan data and uses it to generate unique knitting patterns with specific stitch counts and dimensions tailored to each customer, thereby achieving both high productivity through automation and high manufacturing precision through customization.
Solution Approach 2:
The patent performs preliminary body scanning and measurement capture before the actual knitting production. By obtaining accurate body dimensions in advance and pre-calculating the customized knitting patterns, the system eliminates the need for post-production alterations and ensures precise fit from the first production run, resolving the contradiction between mass production speed and fit consistency.
2Manufacturing precision
If custom-fit information is collected and processed, then manufacturing precision is improved, but device complexity increases due to digital representation and pattern generation systems
Solution Approach 1:
The patent creates a digital copy or replica of the customer's body through scanning technology. This digital body model serves as a precise template for generating knitting patterns, eliminating the need for complex physical measurement processes and manual pattern making, thereby achieving high manufacturing precision with manageable system complexity.
Solution Approach 2:
The patent replaces traditional mechanical measurement tools and manual pattern drafting with automated digital scanning and computer-generated knitting patterns. This substitution of mechanical systems with digital and computational systems streamlines the complexity while maintaining or improving manufacturing precision for custom-fit articles.
3Ease of manufacture
If standardized patterns are used, then ease of manufacture is improved, but adaptability deteriorates due to inability to accommodate individual body shapes
Solution Approach 1:
The patent transforms static standardized knitting patterns into dynamic customized patterns that adapt to individual body shapes. The system automatically generates unique knitting patterns for each customer based on their body measurements, allowing the manufacturing process to remain simple and automated while achieving high adaptability to different body types and sizes.
Data Source
AI summary
Custom-fit versions of knitted articles are produced according to digital representations of objects for which the articles are to be manufactured. The digital representations, optionally augmented by surface fitting algorithms, allow for accurate scaling of pattern-specified stitch counts for pattern elements representing the article taking into account wales and courses densities for the material(s) from which the article is to be made. Displayed dimensionally-accurate representations of the custom-fit articles allow for user-specified style and fit preferences to be made and a final digital pattern of the article to be produced. Machine instructions representing pattern pieces to be knitted are automatically produced from the final digital pattern of the article for a target computerized knitting machine and the custom-fit article then manufactured according to the machine instructions.