Digital Fabric Construction Calculator for Softness Design
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Solution Overview
Problem
The subjective nature of determining fabric 'hand' or 'hand-feel' makes it challenging for manufacturers to develop fabrics that meet customer specifications for softness and smoothness, leading to a time-consuming and costly trial-and-error process, with low match rates between human perception and Fabric Touch Tester measurements.
Innovation Solution
A digital fabric development process using a fabric construction calculator that selects specific fabric parameters such as type, yarn, weight, and finish to achieve a pre-selected softness factor, confirmed by physical testing with a Fabric Touch Tester, allowing for accurate and efficient production of fabrics with desired hand feel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a trial-and-error process is used to match fabric hand feel, then fabric softness and smoothness can be adjusted, but the process becomes time-consuming and costly
Solution Approach 1:
The patent applies preliminary action by establishing a standardized correlation framework between FTT measurements and human hand feel evaluations before actual fabric development begins. This pre-established correlation model allows manufacturers to predict hand feel outcomes without undergoing multiple trial-and-error cycles, thereby reducing development time while maintaining precision.
Solution Approach 2:
The patent implements feedback by creating a standardized correlation system where FTT measurement results are systematically compared with human hand feel evaluations. This feedback mechanism enables continuous refinement of fabric constructions to achieve desired hand feel properties, reducing the need for repeated trial batches and associated time losses.
2Measurement precision
If FTT measurements are used to evaluate fabric properties, then objective data on bending, friction, roughness, compression, and thermal conductivity can be obtained, but the correlation with human hand feel perception remains weak
Solution Approach 1:
The patent applies parameter changes by transforming the correlation between FTT measurements and hand feel perception through standardized scaling and weighting adjustments. By modifying the parameters of the correlation model to better reflect human sensory perception, the system maintains objective measurement precision while improving the accuracy of hand feel prediction.
3Reliability
If multiple fabric samples are produced and tested to achieve desired hand feel, then customer requirements can be met, but manufacturing costs and material waste increase
Solution Approach 1:
The patent applies preliminary action by establishing accurate predictive correlations between FTT measurements and human hand feel before production begins. This allows manufacturers to determine the optimal fabric construction on computer before producing physical samples, significantly reducing the number of samples needed and thereby minimizing material waste while ensuring customer requirements are met.
4Adaptability or versatility
If subjective hand feel evaluation is used, then customer perception can be assessed, but consistency and repeatability of results deteriorate
Solution Approach 1:
The patent introduces an intermediary standardized correlation framework that mediates between subjective hand feel evaluations and objective FTT measurements. This intermediary system translates subjective perceptions into quantifiable data through consistent correlation algorithms, maintaining the ability to assess customer perception while significantly improving evaluation consistency and repeatability across different testers and occasions.
Data Source
AI summary
A process for digitally developing a new fabric and for developing a new fabric based on a physical property of the fabric and rather than a fabric construction. The process comprises selecting a desired physical property of the new fabric and selecting a fabric type. The process also includes using a fabric construction calculator to develop fabric construction parameters for the fabric, wherein the fabric has the desired physical property selected. The desired physical property is a selected softness factor of the fabric.