Using laser to create finishing pattern on apparel
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Solution Overview
Problem
The traditional process of producing distressed denim products is resource-intensive, time-consuming, and environmentally impactful, requiring significant water and chemical usage, such as bleaching or oxidizing agents, to achieve desired wear patterns.
Innovation Solution
A method using software and lasers to reproduce wear patterns on garments by capturing digital images of existing patterns, processing them to control a laser for precise material removal, thereby creating authentic and complex designs on new fabrics with reduced environmental impact and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional water and chemical-based finishing processes are used, then wear patterns can be achieved on denim, but significant water and chemical resources are consumed
Solution Approach 1:
The patent replaces chemical and water-based finishing processes with a laser-based mechanical/thermal system. The laser directly ablates or alters the denim fabric to create wear patterns, eliminating the need for water, bleaching agents, oxidizing agents, enzymes, and pumice stone while maintaining authentic wear pattern quality.
Solution Approach 2:
The patent changes the fundamental parameter of the finishing process from chemical concentration and water volume to laser parameters such as power, pulse duration, scanning speed, and wavelength. This allows precise control of material removal to achieve desired wear patterns without consuming water or chemicals.
2Productivity
If traditional finishing processes are used, then wear patterns can be produced, but the process takes significant time and is resource intensive
Solution Approach 1:
The patent substitutes multi-step chemical processes (washing, bleaching, enzyme treatment, stone washing) with a single or few laser processing steps. This consolidation dramatically reduces both processing time and resource consumption while achieving the same aesthetic effect.
3Quantity of substance
If laser is used to create finishing pattern, then water and chemical usage is reduced, but precise control of laser parameters is required
Solution Approach 1:
The patent uses digital image processing to capture reference wear patterns and convert them into laser control files. This copying approach simplifies the control system by using pre-programmed patterns rather than requiring complex real-time parameter adjustments, making the laser system easier to operate while maintaining consistent results.
4Manufacturing precision
If traditional finishing techniques are used, then authentic wear patterns can be achieved, but environmental impact increases
Solution Approach 1:
The patent replaces environmentally harmful chemical processes with a laser system that uses light energy to create wear patterns. This substitution eliminates the discharge of chemical waste into water systems while producing equally authentic-looking distressed denim, significantly reducing environmental impact.
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 approach allows for the efficient and cost-effective reproduction of authentic wear patterns on denim and other fabrics, reducing water and chemical usage while maintaining the aesthetic quality of traditional finishing techniques.
Implementation Method 1
A laser is used to create a finishing pattern on an outer surface of the jeans. Based on the laser input file, the laser removes selected amounts of material from the surface of the first material
Data Source
AI summary
Software and lasers are used in finishing apparel to produce a desired wear pattern or other design. A technique includes determining a fabric's response to a laser, capturing an initial image of a wear pattern on a garment, and processing the initial image to obtain a working image in grayscale. The working image is further processed to obtain a difference image by comparing each pixel relative to a dark reference. The difference image is converted to a laser values image by using the previously determined fabric response to the laser.