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.

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 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.

A method of material casting includes knitting, by a computer-controlled knitting machine, a flexible formwork, where the flexible formwork defines a partially-closed shape having a plurality of topological features, filling the flexible formwork with a casting material, and deforming the flexible formwork with the casting material. In some cases, the method includes removing the casting material from the flexible formwork when the flexible formwork has imparted the shape on the casting material.

A method of material casting includes knitting, by a computer-controlled knitting machine, a flexible formwork, where the flexible formwork defines a partially-closed shape having a plurality of topological features, filling the flexible formwork with a casting material, and deforming the flexible formwork with the casting material. In some cases, the method includes removing the casting material from the flexible formwork when the flexible formwork has imparted the shape on the casting material.

A large-scale additive manufacturing system for printing a structure includes an extrusion system and a knitting system. The extrusion system includes a nozzle configured to receive a supply of structural material and to selectively dispense the structural material in flowable form, and a first gantry configured to move the nozzle along toolpaths defined according to a structure to be printed such that structural material may be dispensed along the toolpaths to print a series of structural layers, wherein the series of structural layers bond together to form all or a portion of the structure. The knitting system includes a tow feeder configured to feed a supply of tow material to a location proximate a current course of loops extending above an upper surface of a current structural layer or extending above a base surface in regions where no structural layer has been printed, and a hooking device configured to engage the tow material and bring it through the current course of loops to form a subsequent course of loops interwoven with the current course of loops. A controller is configured to operate the knitting system to form additional subsequent courses of loops each interwoven with a current course of loops after each of the series of structural layers are printed, wherein the interwoven courses of loops create a reinforcement network of knitted loops embedded in the structure, and wherein the series of structural layers are tied together.

The invention provides a system for performing dynamic production and knitting machine work management comprising a production demand management unit, an advanced scheduling management unit, a cloth pattern storage unit and a manufacturing execution unit. The production demand management unit receives at least one production demand data. The advanced scheduling management unit generates a production scheduling data according to working conditions of a plurality of knitting machines and the production demand data. The cloth pattern storage unit stores a plurality of knitting machine work setting data. The manufacturing execution unit controls each knitting machine to extract one of the plurality of knitting machine work setting data from the cloth pattern storage unit based on a production cloth pattern data. The knitting machine work setting data is forcibly deleted by the knitting machine when a knitting number meets a set value defined by the knitting number limiting data.

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 fabric file release system for automatically calibrating a circular knitting machine includes a file release end which memorizes a plurality of fabric file and a controlled terminal in information connection with the file release end. Each of the plurality of fabric file comprises a plurality of knitting machine working marks and a plurality of setting parameter values respectively corresponding to one of the knitting machine working marks. The controlled terminal comprises a setting file of knitting machine working including the plurality of knitting machine working marks and a plurality of working parameter values respectively corresponding to one of the knitting machine working marks. The controlled terminal receives one of the fabric file and maps the setting parameter values corresponding to each of the knitting machine working marks to the working parameter values corresponding to each of the knitting machine working marks in the setting file of knitting machine working.