Energy-saving Production Technologies for Brassiere Cup

The intimate apparel industry has adopted a conventional trial and error approach to design and develop bra cup mold. Due to the lack of proper guidelines and knowledge, quality issues have occurred during the production of bra cup molding (e.g. post-mold shrinkage, cup crazing, cup de-lamination, barre mark and moire pattern). It always requires several rounds of re-machining and testing to overcome the above molding problems.

This project has successfully reduced energy and material wastes during the manufacturing process of the brassiere cup and has increased productivity. The solution assists brassiere cup manufacturers on the issues of production tool design and development.

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Application

A CAE analysis in heat transfer can identify the effective heating zone of brassiere cup mold and insulation to reduce heat lost. The industry can take reference from the Molding and Lamination Technology Handbook for Lingerie Industry to eliminate and minimise the trial and error in mold design and fabrication.

Technological Breakthrough

The CAD/CAM/CAE and knowledge-based engineering (KBE) technologies help streamline the manufacturing process in order to significantly increase the productivity. Different advantages of different deliverables are found:

  • Standardised configuration of mold inserts can facilitate the rapid fabrication of brassiere cup mold and save material cost.
  • A molding machine with auto-loader system can reduce the idle time in production of brassiere cups, reduce the human resources and thus increase the productivity.
  • Computer Aided Engineering (CAE) for the simulation of heat transfer in brassiere cup molding process can optimise the heat distribution for better product quality and energy saving.
  • The handbook which lays down brassiere cup molding guidelines can optimise the efficiency in the brassiere cup mold design and fabrication.

Industry Benefit

This project helps local brassiere cup manufacturers to develop an energy-saving and environmental-friendly manufacturing process, the process can be standardised and automated. Manufacturers can save material cost and improve the product quality, and finally increase the industry competitiveness.

For major achievements, the development of a standardised mold library and customised CAM system can help manufacturers save around 40% of aluminum material. The semi-automatic loading system can reduce 30% – 50% number of operators.

Licensing Details

A non-exclusive license includes a brasserie cup molding solution and/or a molding machine with auto-loader system.

The research deliverable is now open for licensing. For more details, please contact us. (Email: info@hkrita.com ; Tel: (852) 2627 0180)