Fabric Printing on Nested Patterns to Reduce Waste and Increase Yield
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Solution Overview
Problem
Conventional fabric printing methods result in substantial waste and poor cutting yields due to the lack of prior knowledge about fabric element geometries and the constraints between pattern geometries and textile sheet prints.
Innovation Solution
A method that involves effective nesting of fabric during the textile cutting process, where designs and graphic elements are directly printed on the nested elements instead of the entire textile sheet, using a blank textile roll and printing only in the geometry areas of the patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional fabric printing methods are used where designs are printed on entire textile sheets before nesting, then the printing process is simple and straightforward, but substantial waste occurs and cutting yields are poor due to lack of knowledge about fabric element geometries
Solution Approach 1:
The patent applies preliminary action by performing nesting of fabric elements before the printing process. The system calculates optimal nesting arrangements of garment patterns on the fabric roll, determines the specific geometries and positions of fabric elements in advance, and only then prints the designs on those nested elements. This reverses the conventional sequence and enables waste reduction through geometry-aware printing.
Solution Approach 2:
The patent implements local quality by printing designs only on the specific nested fabric elements that will be used for garment production, rather than printing on entire textile sheets. Each fabric element receives printing tailored to its specific geometry, position, and orientation in the nested arrangement, optimizing fabric utilization and eliminating waste areas.
2Productivity
If fabric is pre-printed with designs before nesting, then the printing workflow is straightforward, but constraints between pattern geometries and textile sheet prints result in poor cutting yields
Solution Approach 1:
The system performs preliminary nesting calculation and geometry determination before printing. By calculating the optimal arrangement of fabric elements and their geometries in advance, the system eliminates constraints between pattern geometries and print designs, enabling high cutting yields while maintaining manufacturing efficiency.
Solution Approach 2:
The patent introduces dynamics by making the printing process adaptive to the calculated nesting arrangement. The printing parameters, including design positioning, scaling, and orientation, are dynamically adjusted based on the specific geometry and position of each nested fabric element, rather than using fixed print layouts.
3Loss of substance
If designs are printed on entire textile sheets, then printing is simple but there is no prior knowledge of specific fabric element geometries leading to waste
Solution Approach 1:
The system recovers and utilizes fabric element geometry information through preliminary nesting calculation. By determining the specific geometries, positions, and orientations of fabric elements before printing, the system eliminates information loss and enables precise printing that matches each element's geometry, reducing waste.
Data Source
AI summary
Disclosed are methods that couple effective nesting of fabric, as part of a textile cutting process, in which designs and/or graphic elements are directly printed on the nested elements, instead of on the entire textile sheet. Embodiments of the invention can address issues of waste and redundant printing, such as by starting with a blank textile roll, and printing only in the geometry areas of the patterns. Embodiments of the invention can increase fabric yield, because there are no constraints between the pattern geometries and the textile sheet print.