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.

A method of constructing a compression garment, for example, a sock, formed of a knitted fabric that includes an elastomer compression inlay yarn introduced into a predetermined first selection of needles on a first knitting machine finger position and first and second pattern yarns introduced into a predetermined second selection of needles on second and third knitting machine finger positions, the first selection of needles and the second selection of needles collectively defining a predetermined pattern. When the predetermined second selection of needles is raised to take on the first and second pattern yarns, the elastomer compression inlay yarn deflects predetermined ones of the second selection of needles radially inwardly to define an annular space into which the pattern yarns are dropped in an offset relation to the elastomer compression inlay yarn. The first and second pattern yarns are plated to respective outer and inner surfaces of the fabric, and the elastomer compression yarn are inlaid to the inner surface of the fabric.

The invention provides a circular knitting machine for prompting a knitting machine status instantaneously based on a cloth surface status of a fabric, comprising a needle cylinder, a camera module capable of photographing the fabric during doffing, an information processing unit, and an encoder. A camera lens of the camera module does not rotate with the needle cylinder, and a shooting timing of the camera lens is controlled by photographing signals. The information processing unit receives image data generated by the camera module, and compares the images, when there is a difference between the two consecutive image data on a same vertical line, a knitting machine status is prompted. The encoder generates pulse signals when the needle cylinder rotates, the encoder outputs the pulse signals to the camera module or the information processing unit, and the receiver counts the pulse signals to generate the photographing signals.

Disclosed herein are systems and methods that allow an image of a fabric sample to be captured. The image may be analyzed to extract features, sometimes referred to as a stitch parameter, of the fabric's construction, such the use of one or more stitch types. Using the stitch parameters, a build specification can be selected from a plurality of build specification. Each of the plurality of build specifications may be associated with at least one of a plurality of known fabric constructions. The build specification may be exported and then used to construct a fabric similar to the fabric sample captured in the received image.

Disclosed herein are systems and methods that allow an image of a fabric sample to be captured. The image may be analyzed to extract features, sometimes referred to as a stitch parameter, of the fabric's construction, such the use of one or more stitch types. Using the stitch parameters, a build specification can be selected from a plurality of build specification. Each of the plurality of build specifications may be associated with at least one of a plurality of known fabric constructions. The build specification may be exported and then used to construct a fabric similar to the fabric sample captured in the received image.

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).

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).

Methods for fabrication of articles, in particular knitted articles, using computer-controlled machines. A 3D model of the article is characterized by a 3D polygonal mesh defining a surface of the 3D model. A streamline is drawn on the 3D model, and used to define a set of isolines over the surface described by the 3D polygonal mesh. The isolines are quantized into equidistant points along their respective lengths and a cut line traversing each of the isolines is defined. Courses are defined by connecting quantization points of the isolines based on knitting rules to produce a 2D knitting map containing apexes. Apex attraction may be performed on a first portion of the 2D knitting map by decreasing a spatial distance between respective ones of the apexes. The 2D knitting map is subsequently converted to knitting instructions for a computer-controlled knitting machine.

Disclosed herein are systems and techniques for seamless and scalable piezoresistive matrix-based intelligent textile development using digital flat-bed and circular knitting machines. Disclosed embodiments allow for combining and customizing functional conductive and polyester and spandex yarns, thus allowing for designing the aesthetics and architecting and engineering both the electrical and mechanical properties of the pressure sensing textile. In addition, by incorporating a melting fiber, disclosed embodiments allow for shaping and personalizing a three-dimensional piezoresistive fabric structure that can conform to the human body through thermoforming principles.

Disclosed herein are systems and techniques for seamless and scalable piezoresistive matrix-based intelligent textile development using digital flat-bed and circular knitting machines. Disclosed embodiments allow for combining and customizing functional conductive and polyester and spandex yarns, thus allowing for designing the aesthetics and architecting and engineering both the electrical and mechanical properties of the pressure sensing textile. In addition, by incorporating a melting fiber, disclosed embodiments allow for shaping and personalizing a three-dimensional piezoresistive fabric structure that can conform to the human body through thermoforming principles.