A method of forming an underwire channel of a bra cup contains the steps of: A. providing a first cup layer, a second cup layer, and a channel forming rib; B. stacking a first thermoformed layer of the first cup layer and a second thermoformed layer of the second cup layer together; C. providing a forming mold which includes a first part and a second part each having a cavity; D. heating the forming mold with the first cup layer, the second cup layer, and the channel forming rib stacked together in the cavity; E. opening the forming mold to form a cup portion and a semifinished part of an arcuate underwire channel; F. removing the channel forming rib out of the underwire channel by pulling the extension; G. trimming the semifinished part to form a finished cup; and H. finishing a bra cup.

A process for manufacturing an undergarment having two superimposed textiles, comprising depositing on certain parts of reinforcements (8) comprising a thick layer of a shaped memory foam elastic material, the polymerization of this material and also the shaping of the textiles of the undergarment by thermoforming, characterized in that it comprises a step of depositing, on the entire surface of at least the textiles, a thin layer of an elastic adhesive-bonding material, and then a step of polymerizing this thin layer of adhesive bonding during the thermoforming for shaping, and in that it comprises a step of prior depositing, on the textile receiving the layer of reinforcement (8), of a barrier layer of an elastic material, which is polymerized before the depositing of this reinforcement.

The present disclosure provides for an under-support, which includes curved end portions and a support portion extending between the curved end portion. The support portion includes a plurality of openings. The present disclosure further provides for the under-support embedded in a foam cup. When the disclosed under-support is embedded in a foam cup, the foam extends through the openings in the support portion.

A method of 3D printing a garment can include 3D printing a first filament layer extending in a first direction, and 3D printing a second filament layer over the first filament layer. The second filament layer can extend in a second direction different than the first direction such that the first and second filament layers overlap one another at a plurality of contact points and collectively define a plurality of open cells.