The generation of 3D data for rapid manufactured textiles

Rapid Manufactured (RM) textiles were first proposed by Freedom of Creation in 1999. Initially, these textile type structures were viewed as a novelty of additive manufacturing techniques with no specific application. However, the geometric complexity capabilities of additive manufacturing techniques means that the scope of RM textiles is far greater than initially realised. The research undertaken within this thesis regarding this novel area of textiles and Rapid Manufacturing has shown the scope of RM textiles to lie in the area of high performance and smart textiles. Increasingly, high performance and smart textiles are seen as relevant research areas, with the incentive being the realisation of high performance and smart clothing with increased and desirable functionalities. However, the current manufacture of high performance and smart textiles has been shown to be an arduous process, involving complex manufacturing operations and techniques, fraught with design for manufacture and assembly constraints, which are currently restricting the complexity of the textile structures that can be actually achieved. This research suggests that future additive manufacturing techniques provide an elegant solution to these current manufacturing difficulties and therefore validate the novel research area of RM textiles. This research investigates the generation of 3D RM textile geometric data essential for their manufacture by additive manufacturing techniques. It demonstrates that while the generation of planar or flat sheets of RM textile structures with high levels of geometric complexity can be efficiently created using conventional modelling techniques of Computer Aided Design (CAD) software, the generation of conformal textiles is inefficient, time-consuming and error prone. Further investigations utilising experimental textile modelling software provided an initial methodology for the efficient generation of conformal RM textiles to be established. However, the initial methodology was limited. and restricted the main incentive for the creation of RM textiles, geometric complexity. A further methodology was then presented that addresses these limitations, requiring firstly, the generation of a uniform and equidistant mapping surface mesh, and secondly, a complex geometry mapping tool capable of mapping complex geometry to such a mesh accurately and efficiently. The research demonstrates the complexity of generating the required uniform and equidistant mapping mesh and highlights that currently available meshing techniques are incapable of generating such a mesh structure for all curved surface geometries. The generation of the required mapping mesh structure was then investigated and a novel meshing technique and algorithm developed to attain such surface mesh structures. The work then addresses the mapping of complex geometric 3D data to the surface mesh structures and again develops a technique and system capable of achieving this aim. The research therefore culminates in a complete methodology for the efficient generation of conformal RM textile structures of an increased geometric complexity that will enable further research to be undertaken in the novel area of RM textiles.