Re-engineer apparel manufacturing processes with 3D weaving technology for efficient single-step garment production

Traditional apparel assembly technology—cut and sewn process—requires labor-intensive pre- and post-production. While conventional weaving technology has made efforts to streamline the garment-making process, additional assembly processes are still required—sewing or joining after removing the woven samples from the loom. This challenge in the garment-making process discloses the need for a novel type of advanced textile technology and manufacturing techniques incorporating shaping and assembly capabilities. Exploiting three-dimensional (3D)-to-two-dimensional (2D)-to-3D methodology integrated 3D weaving technology, the 3D woven bra prototype is practically demonstrated in a significantly effective manufacturing process, shaped in one weaving cycle without additional assembly needs. The bra manufacturing process is also assessed by traditional industry loom, and the same efficient manufacturing process is also achieved. This indicates that 3D weaving technology contributes as an innovative manufacturing technology in the apparel industry to facilitate the manufacturing process significantly and eliminates further joining and sewing processes.