Weaving Technologies and Digital Communications Towards 3D-to-2D-to-3D Near- and Zero-Waste Manufacturing: A Future Fashion Factory Case Study

This research relates to 3D-to-2D-to-3D woven advanced manufacturing. The value in advancing the conventional weaving machine’s operational production principles to produce derivative woven products, once valued as an investment for a lucrative return (high-value products) particularly in the composites industry, could then find an opening in tailoring on-loom (conventional weaving machine) fashioning-forms. Thus, opening the application of this exciting approach to using the weave design-engineering principles in conventional weaving machine production/manufacturing in the apparel/fashion sector. Few organizations have the combined knowledge to exploit this opportunity, as typically a team lacks the numerous skills to utilize these 3D-to-2D-to-3D wovens, best done by repurposing the conventional weaving machine’s operational production principles that this research proposes. The case study rationale of this research that combines the works of four AHRC-funded Future Fashion Factory industry partnerships is to showcase how the exploration of digital software systems and communication tools where employed in articulating and navigating the inner mindset of an individual’s visualization of a 3D-form, alongside the conventional weaving machine’s operational production principles, and barriers faced in aligning these with the weave design-engineering remit required for actual production/manufacturing of 3D-to-2D-to-3D. The research methodology employed an action-iterative-design theory toward optimized geometrical forms, utilizing folding and tailored fashioned maquettes; alongside process-parameters, design thinking, on-machine learning, and material agnostic approaches. The synergy of these four projects brought forward key parts, with each a standalone challenge, and concluding results, yet stronger together toward 3D-weaving the future. Leading toward re-engineering weaving parameters and principles, demystifying 3D-wovens for UK weaving mills and their conventional weaving machines operational production principles to diversify in-house technologies toward 3D-to-2D-to-3D wovens to broaden appeal and utilization by future product/fashion/composite design-engineers, alongside deepening the learning of weave design-engineers.