Energy-saving Production Technologies for Brassiere Cup

Project182
The objective of this project is to develop an energy-saving and environmental-friendly manufacturing process for brassiere cup manufacturers. With the aid of Knowledge Based Engineering (KBE) and CAD/CAM/CAE technologies, the overall brassiere cup manufacturing process can be streamlined and the production lead-time can be shortened by at least 60%. This project will focus on four technology application / development stated below: 1) Define and formulate a knowledge based brassiere cup molding guideline to optimize the efficiency in the brassiere cup mold design and fabrication; 2) Standardize the configuration of mold inserts to facilitate the rapid fabrication of brassiere cup mold and also, to save the material cost; 3) Develop a semi-automatic conveyer for loading and un-loading of the synthetic sheet fabric to the mold; and 4) Apply Computer Aided Engineering (CAE) for the simulation of heat transfer in brassiere cup molding process, to optimize the heat distribution for better product quality and energy saving. Ten pilot companies from brassiere cup manufacturing industry are identified. They will participate in the technology development of this project. The project deliverables will benefit local brassiere cup manufacturing industry in technology advancement and energy saving.
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.

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.

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.

Project Name (ITF)
Development of an Innovative Manufacturing Solution for Energy-saving and Environmental-friendly Production of Brassiere Cup
Project Number (ITF)
GHP/048/07TP