System and Method for Creating Custom-Fit Apparel Designs

1 . An automated system for the production of a personalized custom-fit garment, the system comprising:

(a) a scanner configured for obtaining a scan comprising a three-dimensional model of a customer's body shape;

(b) a computer comprising:

(i) memory,

(ii) an input device,

(iii) a processor,

(iv) a network connection, and

(v) a computer-readable storage medium having non-transitory computer instruction code comprising:

(a) sizing algorithms for extracting sizing parameters from the customer's body shape scan and parametrically scaling a selected digital garment design pattern to the customer's body shape;

(b) customization algorithms for enabling a customer to select and incorporate fit and style preferences into the digital pattern; and

(c) visualization algorithms for visualizing in real time the drape and fit of the garment design pattern around a digital representation of the customer's body shape derived from the scanner, and for allowing the customer to interact with and modify design parameters; and

(c) a database comprising a set of digital design patterns contributed by an online designer community; and

(d) an automated garment manufacturing system comprising manufacturing equipment and material handling equipment networked to a central controller.

2 . The system according to claim 1 , wherein the scanner is a non-contact body scanner which generates a three-dimensional representation of the customer's body shape.

3 . The system according to claim 3 , wherein the scanner is a white light scanner, structured white light scanner, eye-safe laser scanner, or a millimeter wave imaging scanner.

4 . The system according to claim 1 , wherein the storage medium further comprises non-transitory computer instruction code comprising nesting algorithms configured for minimizing fabric waste by optimizing arrangement of pattern pieces on the fabric prior to cutting the pattern pieces from the fabric.

5 . The system according to claim 1 , wherein a digital pattern comprises one or more parameters selected from the group consisting of:

(a) a three-dimensional digital geometry of the pattern;

(b) an extrapolated two-dimensional design;

(c) garment sewing and assembly machine instructions;

(d) fabric type and fabric orientation parameters; and

(e) choice and placement of finishes and hardware.

6 . The system according to claim 5 , wherein the finishes and hardware are selected from the group consisting of specialty washes, specialty fabric dyes, rivets, buttons, zippers, snaps, hooks, hook-and-loop fasteners, elastic bands, stitch styles and spacings, custom labels, and embroidery.

7 . The system according to claim 1 , wherein:

(a) the sizing algorithms extract sizing parameters from a three-dimensional point cloud obtained from the customer's body scan, and

(b) the algorithms for parametrically scaling the digital pattern adjust the fit of the garment to the customer's body shape and size.

8 . The system according to claim 1 , wherein the customization algorithms are configured for incorporating one or more customer preferences selected from the group consisting of:

(a) fabric and fabric color selection;

(b) thread selection;

(c) choice of customized hardware;

(d) embroidery selection and placement;

(e) label placement or absence thereof;

(f) design element placement or repositioning; and

(g) choice of customized finishes.

9 . The system according to claim 1 , wherein the visualization algorithms are configured for:

(a) creating a digital avatar of a customer, the digital avatar providing a three-dimensional representation of the customer's body shape;

(b) visualizing a selected digital pattern around the digital avatar;

(c) visualizing fabric draping and fit of the selected digital pattern on the digital avatar; and

(d) retaining customer modifications of drape and fit in the digital pattern for use by the customer in subsequent orders.

10 . A method for creating a personalized custom-fit garment, the method comprising the steps of:

(a) obtaining three-dimensional body measurements of a customer using a non-contact whole-body scanner;

(b) providing the customer with a plurality of digital garment designs from which the customer may select a particular garment design, the digital garment designs obtained from an associated community of designers;

(c) adapting the selected design to the customer's body measurements to obtain a customized design;

(d) incorporating customer style and fit preferences in the customized design to obtain a personalized custom-fit design;

(e) generating a digital pattern for a garment based on the personalized custom-fit design; and

(f) manufacturing the personalized custom-fit garment from the digital pattern using an automated manufacturing process.

11 . The method according to claim 10 , further comprising the steps of:

(d1) displaying a dimensionally-accurate three-dimensional representation of the personalized custom-fit design in real time to a customer, and rapidly updating the three-dimensional representation as the customer selects style and fit preferences.

12 . The method according to claim 10 , further comprising the steps of:

(g) storing the customer's three-dimensional body measurements in a database for subsequent orders; and

(h) preparing subsequent personalized custom-fit garments in accordance with steps (b)-(f) using the stored body measurements.

13 . The method according to claim 10 , further comprising periodically refreshing the digital garment designs with replacement designs.

14 . The method according to claim 10 , further comprising offering a customer an incentive to rescan the customer's body and obtain updated three-dimensional body measurements at a pre-determined time or upon passage of a pre-determined period of time.

15 . The method according to claim 10 , further comprising linking a customer's profile to an online or store account, and providing the customer with an incentive to rescan the customer's body using information obtained from the linked account.

16 . The method according to claim 10 , wherein the garment is a pair of jeans, a pair of pants, shirt, blouse, vest, suit, dress, skirt, undergarment, or hat.

17 . The method according to claim 10 , wherein total garment manufacturing time is about an hour.

18 . The method according to claim 10 , wherein the members of the associated designer community communicate via a website.

19 . The method according to claim 18 , wherein the website:

(a) provides a discussion forum and online tools and software to designers for creation of digital design patterns;

(b) encourages collaboration, sharing, and co-design of digital design patterns; and

(c) provides features to enable prize-based design competitions, display of design popularity and usage statistics, and design and designer peer reputation scores.

20 . The method according to claim 10 , further comprising paying a royalty to a designer of a digital design pattern upon a customer's selection of the designer's digital design pattern.

21 . The method according to claim 10 , wherein a customer style preference is a choice of fabric and fabric direction.

22 . The method according to claim 21 , wherein the fabric is manufactured from woven or non-woven natural fibers, synthetic fibers, or a combination thereof.

23 . The method according to claim 21 , wherein the fabric is selected from the group consisting of denim, cotton, linen, wool, silk, rayon, polyester, nylon, Lycra, and combinations and blends thereof.

24 . The method according to claim 10 , wherein the garment is manufactured by three-dimensional printing, additive manufacturing, adhesive bonding, or knitting.