Bespoke Knitted Compression Garments With Course-Based Pressure Mapping
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Solution Overview
Problem
Existing methods for manufacturing bespoke knitted compression garments struggle to accurately apply clinically predetermined pressures, often requiring human intervention and resulting in inefficiencies and inaccuracies in pressure distribution.
Innovation Solution
A method involving scanning a body part to create a representation of datapoints, fitting curves to these datapoints, calculating course pressures, and determining the number of needles for each course based on material strain and circumference values, allowing for automated production of bespoke compression garments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual methods are used to determine pressure distribution and garment construction, then some level of customization is achieved, but manufacturing precision and accuracy of pressure application are insufficient
Solution Approach 1:
The patent replaces manual measurement and calculation methods with automated optical scanning and computer-based processing. A scanner captures 3D coordinates of the body part, and a processor automatically calculates pressure distribution and garment construction parameters, eliminating human error and improving precision.
Solution Approach 2:
The patent creates a digital replica (point cloud model) of the patient's body part through scanning. This digital copy is then used for all subsequent measurements, calculations, and garment design, allowing precise reproduction of the required pressure distribution without manual intervention.
2Productivity
If bespoke compression garments are manually designed and manufactured, then accurate pressure application can be achieved, but manufacturing speed and productivity are reduced
Solution Approach 1:
The patent replaces slow manual design and calculation processes with automated computer-based systems. The processor rapidly generates knitting patterns and pressure distribution calculations from scanned data, dramatically increasing manufacturing speed while maintaining or improving precision through algorithmic accuracy.
Solution Approach 2:
The patent performs all measurements, calculations, and pattern generation in advance during the manufacturing process. The digital model and knitting patterns are prepared before production, allowing the actual garment manufacturing to proceed quickly without interruptions for manual adjustments or fittings.
3Manufacturing precision
If compression garments are made with uniform course construction, then manufacturing is simpler, but the ability to apply clinically predetermined pressure distribution is compromised
Solution Approach 1:
The patent applies different knitting parameters (needle selection, course density, stitch patterns) to different sections of the garment based on the locally calculated pressure requirements. Each horizontal course is customized according to the specific pressure needed at that location on the body part, achieving precise pressure distribution through localized construction variations.
Solution Approach 2:
The patent divides the compression garment into multiple horizontal courses or bands, each with independently calculated knitting parameters. This segmentation allows the garment to apply different pressures at different levels, matching the clinical pressure distribution requirements while maintaining a systematic manufacturing approach.
4Productivity
If automated scanning and data processing are implemented, then manufacturing precision and speed are improved, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where the scanner, processor, and knitting machine control work together as a unified automated production line. The same digital model generated by the scanner is used for pressure calculation, pattern generation, and manufacturing control, eliminating the need for separate manual processes and reducing overall system complexity despite the advanced technology involved.
Data Source
AI summary
A method of making a bespoke knitted compression garment. The method comprises providing a representation of a body part on which the compression garment is to be worn (S102), the representation comprising a plurality of datapoints. A desired pressure configuration to be applied by the compression garment on the body part is determined (S104). Representation courses around the representation are defined (S106). Sets of datapoints for each representation course are selected (S107). A curve for each set of datapoints and a circumference value of each curve is calculated (S108, S109). A pressure to be applied by each course is determined (S111) and a material for knitting, and a number of needles for each representation course, is determined based on the course pressure of the associated material course, a strain characteristic of the material, and the circumference value of the associated curve (S112). A garment is knitted according to the number of needles and the material (S113, S114).