Systems and methods for producing textiles
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Solution Overview
Problem
Current textile manufacturing processes involve inefficient and costly methods for decorating blank goods, including high setup costs for screen printing and high per-print costs for Direct to Garment printing, with limitations on fabric types and print durability.
Innovation Solution
The proposed system integrates digital textile printing, numeric control cutting, and robotic sewing by receiving image data for textile products, synchronizing material transit rates, and assembling products directly from printed and cut sewing pattern pieces, allowing for concurrent fabric colorization and patterning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If screen printing is used for decorating blank goods, then production efficiency is improved, but setup costs increase
Solution Approach 1:
The patent changes the fundamental parameter of the printing approach from traditional screen printing to digital textile printing. This allows the system to maintain high production efficiency while eliminating the high setup costs associated with screen printing, as digital printing requires no physical screens or complex setup procedures.
Solution Approach 2:
The patent replaces the mechanical screen printing system with a digital printing system. Instead of using physical screens, stencils, and manual or semi-automated printing mechanisms, the invention uses digital textile printers that can directly print designs onto fabric, thereby reducing setup complexity and costs while maintaining productivity.
2Device complexity
If Direct to Garment printing is used, then setup costs are reduced, but per-print costs increase
Solution Approach 1:
The patent changes the printing medium parameter from printing on finished garments to printing on flat textile material before cutting and sewing. This allows for more efficient ink application and reduces per-print costs while maintaining the simplicity of digital printing setup.
Solution Approach 2:
The patent performs the printing action before the cutting and sewing processes, rather than after garment assembly. By printing on flat textile material first, the system achieves better ink penetration and coverage efficiency, reducing material waste and per-print costs while maintaining low setup requirements.
3Ease of manufacture
If traditional decorating processes are used, then fabric type limitations are imposed, but process simplicity is maintained
Solution Approach 1:
The patent makes the digital textile printing system universal across multiple fabric types. The system can print on various textiles including cotton, polyester, blends, and other materials without requiring process changes, thereby eliminating fabric type limitations while keeping the digital printing process simple and consistent.
Solution Approach 2:
The patent changes the printing approach to digital textile printing, which uses digital control and adjustable parameters to adapt to different fabric types. This allows the system to maintain process simplicity while achieving versatility across various textiles through software control and parameter adjustment rather than physical process changes.
4Productivity
If conventional printing methods are used, then print durability is limited, but production speed is maintained
Solution Approach 1:
The patent replaces conventional mechanical printing methods with digital textile printing technology. This substitution enables the system to maintain high production speed while achieving superior print durability through precise digital ink application, better ink-fabric bonding, and consistent quality control that conventional methods cannot achieve.
Data Source
AI summary
Systems and methods for producing printed goods from textile material to address shortcoming of existing approaches for article production. According to the systems and methods described herein, the harvested and woven cotton may be shipped directly to garment decorators who may perform all remaining steps to provide customers with finished goods. As such, the systems and methods herein may eliminate the steps of the blank goods trade and current manufacturing processes.