Systems and methods for automatically producing a cord structure are provided herein. In one embodiment, a method comprises automatically forming, with at least one robotic arm, a first plurality of loops in a first plane, and automatically forming, with the at least one robotic arm, a second plurality of loops in a second plane orthogonal to the first plane, the second plurality of loops slippably engaged with the first plurality of loops. In this way, cord structures may be quickly constructed, thereby reducing labor input and expense.

A process for digitally developing a new fabric and for developing a new fabric based on a physical property of the fabric and rather than a fabric construction. The process comprises selecting a desired physical property of the new fabric and selecting a fabric type. The process also includes using a fabric construction calculator to develop fabric construction parameters for the fabric, wherein the fabric has the desired physical property selected. The desired physical property is a selected softness factor of the fabric.

Custom-fit versions of knitted articles are produced according to digital representations of objects for which the articles are to be manufactured. The digital representations, optionally augmented by surface fitting algorithms, allow for accurate scaling of pattern-specified stitch counts for pattern elements representing the article taking into account wales and courses densities for the material(s) from which the article is to be made. Displayed dimensionally-accurate representations of the custom-fit articles allow for user-specified style and fit preferences to be made and a final digital pattern of the article to be produced. Machine instructions representing pattern pieces to be knitted are automatically produced from the final digital pattern of the article for a target computerized knitting machine and the custom-fit article then manufactured according to the machine instructions.

Custom-fit versions of knitted articles are produced according to digital representations of objects for which the articles are to be manufactured. The digital representations, optionally augmented by surface fitting algorithms, allow for accurate scaling of pattern-specified stitch counts for pattern elements representing the article taking into account wales and courses densities for the material(s) from which the article is to be made. Displayed dimensionally-accurate representations of the custom-fit articles allow for user-specified style and fit preferences to be made and a final digital pattern of the article to be produced. Machine instructions representing pattern pieces to be knitted are automatically produced from the final digital pattern of the article for a target computerized knitting machine and the custom-fit article then manufactured according to the machine instructions.

Systems and methods for automatically producing a cord structure are provided herein. In one embodiment, a method comprises automatically forming, with at least one robotic arm, a first plurality of loops in a first plane, and automatically forming, with the at least one robotic arm, a second plurality of loops in a second plane orthogonal to the first plane, the second plurality of loops slippably engaged with the first plurality of loops. In this way, cord structures may be quickly constructed, thereby reducing labor input and expense.

Methods to increase structural performance, strength, and durability of textile-reinforced composite materials are provided. The textile reinforcement may be knitted, for example, in a flat bed weft knitting machine. The method may include pre-stressing a textile reinforcement preform by applying tension. A polymeric precursor may be introduced to the pre-stressed textile reinforcement preform. The polymeric precursor may then be cured or consolidated, followed by releasing of the applied tension to form the composite article comprising polymer and the pre-stressed textile reinforcement. In other aspects, a composite article is provided that has a pre-stressed textile reinforcement structure and a cured polymer. The textile reinforcement may be a knitted, lightweight, seamless, unitary structure. The knitted reinforcement structure may have distinct first and second knitted regions with different levels of pre-stress, thus providing enhanced control over strength, rigidity, and flexibility of the composite article.

Methods to increase structural performance, strength, and durability of textile-reinforced composite materials are provided. The textile reinforcement may be knitted, for example, in a flat bed weft knitting machine. The method may include pre-stressing a textile reinforcement preform by applying tension. A polymeric precursor may be introduced to the pre-stressed textile reinforcement preform. The polymeric precursor may then be cured or consolidated, followed by releasing of the applied tension to form the composite article comprising polymer and the pre-stressed textile reinforcement. In other aspects, a composite article is provided that has a pre-stressed textile reinforcement structure and a cured polymer. The textile reinforcement may be a knitted, lightweight, seamless, unitary structure. The knitted reinforcement structure may have distinct first and second knitted regions with different levels of pre-stress, thus providing enhanced control over strength, rigidity, and flexibility of the composite article.

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.

Apparel patterns may be generated as a function of custom apparel information provided by a user, such as one or more measurements, colors, etc., such that the user can have apparel custom-knitted to their particular size and shape without having to acquiesce the high expense and long wait times typically associated with custom-fit clothing. After a custom apparel pattern is generated, a custom-knitted article can be manufactured based on the pattern by transmitting appropriate information to a knitting machine. Data produced while generating custom apparel patterns can be stored and used to optimize and improve the manufacturing of customized knitwear for subsequent users. Further, such data can be shared with third parties such that manufacturers or others can utilize one or more beneficial aspects of the present disclosure without having to implement all of the functionality that would otherwise be required to obtain such benefits.