Knitted Component Deformation Compensation for Custom Fabrication
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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, which result in fabric deformations and increased waste.
Innovation Solution
A digital customization system that utilizes a computational parametric tool to predict and compensate for fabric deformations by creating a library of knitted structures and employing a physical simulation to estimate deformation, allowing for dynamic adjustments in the design process, thereby improving the accuracy and efficiency of the knitting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional knitting systems are used with separation of design and manufacturing processes, then design flexibility is maintained, but manufacturing efficiency deteriorates due to multiple iterative cycles
Solution Approach 1:
The patent merges the design and manufacturing processes by implementing a digital knitting system where the knitting machine is directly controlled by digital design data. This integration eliminates the separation between design and manufacturing, allowing real-time simulation and prediction of fabric behavior during the design phase, thereby reducing iterative cycles and improving manufacturing efficiency while maintaining design flexibility.
Solution Approach 2:
The patent applies preliminary action by performing simulation and prediction of fabric deformation and behavior during the design phase, before actual manufacturing begins. The system pre-calculates the required needle operations and stitch patterns to achieve the desired final fabric dimensions, compensating for expected deformations in advance. This preliminary computation prevents the need for multiple physical iteration cycles.
2Manufacturing precision
If manual iterative testing is performed to achieve accurate fabric dimensions, then manufacturing precision is improved, but time consumption increases
Solution Approach 1:
The patent replaces manual iterative testing with an automated computational system that uses digital models and algorithms to simulate fabric behavior. The system substitutes mechanical trial-and-error with computer-based prediction and calculation, automatically determining the optimal knitting parameters and stitch patterns to achieve precise fabric dimensions without time-consuming physical iterations.
Solution Approach 2:
The patent creates a digital copy or virtual model of the knitting process and fabric behavior. Instead of physically manufacturing multiple test samples, the system uses computational simulations to replicate and analyze fabric deformation and dimensions virtually. This digital copying allows for rapid iteration and optimization of design parameters before actual manufacturing, significantly reducing time consumption while maintaining precision.
3Adaptability or versatility
If complex multiple structured knits are manufactured without deformation prediction, then design complexity is achieved, but fabric deformation increases
Solution Approach 1:
The patent implements feedback by continuously monitoring and analyzing the relationship between stitch structures and resulting fabric deformation through computational simulation. The system uses the simulated feedback information to automatically adjust knitting parameters, needle operations, and stitch patterns, ensuring that complex multi-structured knits achieve the desired dimensions without excessive deformation. This closed-loop feedback mechanism enables precise control of fabric behavior in complex designs.
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting knitting parameters such as stitch density, needle selection, yarn tension, and pattern repetition based on the simulated deformation analysis. When the system predicts that certain stitch combinations will cause excessive deformation, it automatically modifies the relevant parameters to compensate, allowing complex multi-structured knits to be manufactured with controlled deformation and high precision.
Data Source
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. The system may manufacture/fabricate a knitted component based on the predicted/estimated deformation behavior of the knit.