Population-Based Eyewear Variants for Fit and Manufacturing Efficiency
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Solution Overview
Problem
Conventional wearable products, such as eyewear, are often mass-produced in a single size, leading to issues with alignment, comfort, and aesthetics, while fully customized solutions are time-consuming and complex to set up.
Innovation Solution
A computing device uses population-based sizing to generate a discrete set of variants of wearable objects, constrained by customization, fitting, and manufacturing constraints, allowing for efficient production and alignment with user anatomy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mass production with single size is used, then manufacturing efficiency is improved, but fit quality and alignment deteriorate
Solution Approach 1:
The patent applies parameter changes by creating multiple discrete size variants (S, M, L, XL, etc.) from a baseline design, where each variant has modified dimensional parameters such as frame width, lens size, and temple length. This allows the system to maintain efficient manufacturing through standardized processes while providing fit quality improvements by selecting the appropriate size variant for different user populations.
Solution Approach 2:
The patent segments the continuous size spectrum into discrete size categories (small, medium, large, extra large). This segmentation approach divides the population into different size groups, each receiving a tailored variant, thereby improving fit quality while maintaining manufacturing efficiency through standardized production of each discrete size type.
2Manufacturing precision
If multiple pre-determined sizes are provided, then alignment quality is improved, but inventory complexity and production cost increase
Solution Approach 1:
The patent creates a universal baseline design that can be adapted to multiple size variants through parametric modifications. This universal design framework allows the same manufacturing processes and tooling to produce different size variants, reducing inventory complexity and production costs while maintaining alignment quality across all size categories.
Solution Approach 2:
The patent implements a moderate number of discrete size variants (5-10 sizes) rather than offering every possible size combination. This partial action approach provides sufficient alignment quality for the majority of the population while avoiding the excessive inventory complexity and production costs that would result from offering a complete continuous size range.
3Manufacturing precision
If fully customized eyewear is manufactured using 3D printing, then fit quality is improved, but manufacturing time and setup complexity increase
Solution Approach 1:
The patent performs preliminary actions by pre-calculating and pre-defining the optimal discrete size variants for different user populations based on population data and facial measurements. This preliminary sizing analysis allows for rapid selection of the appropriate variant without requiring time-consuming 3D scanning and customization for each individual, thereby improving fit quality while reducing manufacturing time.
Solution Approach 2:
The patent creates standardized copies of the baseline design in different discrete sizes rather than generating unique custom designs for each user. These copied variants can be produced using efficient manufacturing processes including injection molding and 3D printing, maintaining fit quality through proper size selection while significantly reducing manufacturing time and setup complexity compared to fully customized approaches.
Data Source
AI summary
Certain aspects provide a method for creating a discrete set of variants of a customizable wearable object, comprising: receiving a baseline 3D design file for a baseline 3D customizable wearable object; obtaining a fitting population comprising a set of 3D anatomy models representing potential wearers of the customizable wearable object; generating a plurality of modified 3D customizable wearable objects based on fitting the baseline 3D customizable wearable object to each 3D anatomy model of the set of 3D anatomy models; selecting one or more of the plurality of modified 3D customizable wearable objects as the discrete set of variants of the customizable wearable object; and generating a set of 3D design files corresponding to the discrete set of variants of the customizable wearable object.