Creating made-to-order items with embellishments
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for applying heat transfer embellishments to made-to-order garments, such as those described in U.S. Pat. No. 11,046,068, are inefficient and costly due to the need for batch processing, registration symbols, and consistent placement patterns, which restrict flexibility and increase processing steps.
Innovation Solution
A process that associates a tray with a specific made-to-order item request, places embellishments on the tray, loads the item onto a lower platen, and uses a controlled matrix of vacuum ports to precisely place each embellishment on the garment, allowing for variable placement patterns and eliminating the need for registration symbols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If batch processing with consistent placement patterns is used, then manufacturing process stability is improved, but productivity deteriorates due to multiple batches required for different placement patterns
Solution Approach 1:
The system dynamically adjusts the embellishment placement pattern for each garment based on its specific characteristics. The controller receives garment data, determines the appropriate placement pattern, and guides the robotic system to place embellishments accordingly, allowing each garment to be processed according to its unique requirements rather than forcing all garments into fixed batches.
Solution Approach 2:
The system changes the placement parameters (positions, orientations, and selection of embellishments) based on garment-specific data. The controller modifies placement patterns dynamically for each garment, enabling single-garment processing with variable placement requirements without requiring multiple batches with different fixed patterns.
2Manufacturing precision
If registration symbols are used for precise placement, then manufacturing precision is improved, but device complexity worsens due to additional marking and detection systems
Solution Approach 1:
The garment itself provides the reference information needed for precise placement through its unique identifiers and characteristics. The system reads garment data (such as size, style, and specific placement requirements) directly from the garment or its associated data, eliminating the need for separate registration symbols and their detection systems.
Solution Approach 2:
The system replaces mechanical registration symbols with a data-based approach. Instead of using physical marks on the garment that require optical detection, the system uses digital garment data and machine vision to identify and place embellishments precisely based on the garment's characteristics and stored placement specifications.
3Manufacturing precision
If multiple batches with different placement patterns are processed separately, then manufacturing precision is maintained, but loss of time increases due to batch reconfiguration
Solution Approach 1:
The system maintains continuous processing by eliminating batch reconfiguration steps. Each garment is processed individually with its specific placement pattern applied directly without requiring the system to stop, reconfigure, or switch between batches. The controller continuously receives garment data and adjusts placement parameters in real-time, maintaining uninterrupted production flow.
Solution Approach 2:
The placement patterns and garment specifications are predetermined and stored in the system before processing begins. The controller has access to placement patterns for different garment types and sizes, allowing immediate application of the correct pattern without reconfiguration during processing.
4Ease of manufacture
If consistent component placement is required, then ease of manufacture is improved, but adaptability worsens due to inability to handle variable placement patterns
Solution Approach 1:
The system is designed to be dynamic and adaptive, automatically adjusting embellishment placement based on garment-specific data. The controller receives information about each garment's size, style, and placement requirements, then guides the robotic system to place embellishments according to the appropriate pattern, eliminating the need for fixed batch processing while maintaining manufacturing simplicity through automation.
Solution Approach 2:
The system is designed to handle multiple garment types, sizes, and placement patterns using a single integrated process. The controller can manage different placement patterns and the robotic system can adapt to various garment characteristics, providing universal capability across different jersey styles without requiring separate manufacturing lines or complex batch reconfiguration.
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 process enables efficient and flexible application of heat transfer embellishments to made-to-order garments, reducing costs and improving throughput by allowing for asynchronous order processing and variable placement patterns.
Implementation Method 1
using a controlled matrix of vacuum ports to pick up a particular embellishment from the tray and position the particular embellishment on a target location
Implementation Method 2
applying heat and pressure to bind the subset of embellishments for placement on the first portion of the item to be customized
Implementation Method 3
applying heat and pressure to bind the subset of embellishments
Data Source
AI summary
Binding a set of embellishments to an item as part of a made-to-order item request. Loading the item onto a lower platen so that the first portion of the item is positioned to receive the subset set of embellishments for placement on the first portion of the item. Advancing the lower platen and the tray to a pick & place station. Using a controlled matrix of vacuum ports to pick up a particular embellishment from a tray and position the particular embellishment on a target location for the particular embellishment on the lower platen that is loaded with the item. Repeating for each additional embellishment for the subset of embellishments for placement on the first portion of the item to be customized are all placed. Applying heat and pressure to bind the subset of embellishments for placement on the first portion of the item.