Knitted Component Customization Using Predictive Deformation Models

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Solution Overview

Problem

Conventional knitting systems face inefficiencies in designing and manufacturing knitted components due to the lack of direct link between design and manufacturability, leading to time-consuming and costly iterative processes, especially when dealing with complex multiple structured knits, resulting in fabric deformations and increased waste.

Innovation Solution

A digital customization system that utilizes a library of knitted structures and a comprehensive computational predictive model to estimate and compensate for deformations, allowing for dynamic design adjustments and improved automation of the knitting process, thereby reducing manual intervention and enhancing the accuracy and speed of knitted product manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional knitting systems are used with separate design and manufacturing processes, then design flexibility is maintained, but manufacturing efficiency decreases and iterative cycles increase

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoiditerative cycle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent combines the design software and manufacturing control into a single integrated system. The design software directly generates knitting machine instructions without requiring separate programming steps, merging the design and manufacturing processes to eliminate iterative cycles and improve productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system performs preliminary simulation of the knitting process within the design software before actual manufacturing. This allows potential issues to be identified and resolved in the design phase, preventing costly iterative rework during production and reducing overall manufacturing time.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If digital control tools are used for customization of knitted fabrics, then design precision improves, but fabrication complexity increases due to physical deformations

Engineering Contradiction:

Improvedesign accuracyVSAvoidfabrication process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system incorporates deformation compensation algorithms that calculate and correct for fabric distortion before the knitting process begins. By pre-compensating for expected deformations in the digital design phase, the system maintains manufacturing precision while avoiding the need for complex manual adjustments during fabrication.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system creates a digital twin or virtual model of the knitting process that replicates physical behavior. This digital copy allows for simulation and prediction of fabric deformations, enabling precise control without requiring complex physical trial-and-error processes.

Inventive Principle:

Principle #26Copying

3Manufacturing precision

If manual testing and iteration are performed to achieve accurate knit designs, then fabric deformation control improves, but production speed decreases and waste increases

Engineering Contradiction:

Improvefabric deformation controlVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system uses virtual simulation to replicate the physical knitting process and predict fabric behavior before actual production. This digital copying allows for accurate deformation control to be achieved in the virtual environment, eliminating the need for multiple physical test iterations and thereby increasing production speed while reducing waste.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces manual physical testing with automated computational simulation. The simulation engine predicts fabric deformation and allows for virtual adjustments, substituting mechanical trial-and-error with digital analysis to maintain precision while dramatically improving production speed and reducing material waste.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If complex multiple structured knits are manufactured using conventional processes, then design versatility is achieved, but fabrication difficulty increases and requires highly trained individuals

Engineering Contradiction:

Improvedesign versatilityVSAvoidfabrication ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The system merges design creativity with automated manufacturing control in a single software platform. This integration allows complex multi-structured knit designs to be created and manufactured without requiring highly trained operators, as the software automatically manages the complexity of coordinating different stitch structures and patterns.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11421355B2Tool for design and fabrication of knitted components

Publication Date: 2022.08.23 NIKE INC

AI summary

Computer based systems and methods for designing and manufacturing consumer products, including knit footwear uppers, and the like. The system provides digital controls for the customization of knitted components, including complex multi-structured knitted components. The system simulates deformations of knit structures and allows the user to control and visualize compensations in the structure(s) of the knitted component to better match between an intended knit design and the actual physical knitted component outcome. They system may manufacture/fabricate a knitted component based on the predicted/estimated deformation behavior of the knit.