Digital design tool with image preview in web browser
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Solution Overview
Problem
The traditional process of producing jeans with wear patterns is resource-intensive, time-consuming, and environmentally costly, requiring significant water and chemical usage.
Innovation Solution
A software and laser-based system that allows users to create, preview, and apply wear patterns on jeans, enabling real-time modification and application of designs directly onto the fabric using a laser, reducing the need for extensive water and chemical usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional water and chemical-based finishing techniques are used, then wear patterns can be achieved on jeans, but resource consumption and environmental impact increase significantly
Solution Approach 1:
The patent replaces chemical and water-based finishing processes with a laser-based system. The laser device applies energy directly to the denim fabric to create wear patterns, eliminating the need for water, chemicals, and traditional mechanical abrasion processes while achieving the same aesthetic effect.
Solution Approach 2:
The patent changes the fundamental parameter of the finishing process from chemical/water-based to energy-based (laser). By controlling laser parameters such as power, speed, and pattern, the system achieves precise wear pattern creation without consuming water or chemicals, directly resolving the contradiction between quality and resource consumption.
2Manufacturing precision
If traditional finishing processes are used, then wear patterns can be produced, but processing time and costs increase
Solution Approach 1:
The laser-based system replaces multiple sequential traditional processes (abrasion, washing, chemical treatment) with a single direct energy application process. This substitution dramatically reduces processing time while maintaining or improving wear pattern quality through precise digital control of the laser parameters.
Solution Approach 2:
The system uses computer-generated laser input files that predefine the exact wear pattern to be created. This preliminary digital planning allows the laser to directly create the final wear pattern in one pass, eliminating the need for multiple iterative processing steps required by traditional methods.
3Manufacturing precision
If traditional finishing techniques are used, then wear patterns can be achieved, but the process is resource-intensive and environmentally costly
Solution Approach 1:
The patent substitutes harmful chemical and water-based processes with a clean laser energy process. The laser creates wear patterns through controlled thermal energy that vaporizes or frays fibers locally, producing no chemical waste, water pollution, or harmful emissions, thereby eliminating the environmental harm associated with traditional finishing.
Solution Approach 2:
The patent converts the potentially harmful effect of laser energy (thermal damage) into a beneficial process by precisely controlling the energy input to create realistic wear patterns. The localized thermal effect that could be harmful is instead used to achieve the desired aesthetic effect without the harmful byproducts of chemical processes.
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 reduces processing time and environmental impact while maintaining the desired look and style of traditional finishing techniques, allowing for efficient and cost-effective production of jeans with customizable wear patterns.
Implementation Method 1
The laser removes a selected amount of the surface of the indigo dyed yarn... The laser removes the dyed fibers, which can be by vaporizing or otherwise destroying the cotton fiber via heat or high temperature that the laser beam causes.
Implementation Method 2
The laser removes the dyed fibers, which can be by vaporizing or otherwise destroying the cotton fiber via heat or high temperature that the laser beam causes.
Implementation Method 3
The laser removes the dyed fibers, which can be by vaporizing or otherwise destroying the cotton fiber via heat or high temperature that the laser beam causes.
Data Source
AI summary
A tool allows a user to create new designs for apparel and preview these designs before manufacture. Software and lasers are used in finishing apparel to produce a desired wear pattern or other design. Based on a laser input file with a pattern, a laser will burn the pattern onto apparel. With the tool, the user will be able to create, make changes, and view images of a design, in real time, before burning by a laser. Input to the tool includes fabric template images, laser input files, and damage input. The tool allows adding of tinting and adjusting of intensity and bright point. The user can also move, rotate, scale, and warp the image input.