Abstract
Three-dimensional knitted uppers for footwear enhance ergonomic properties and fit compared to conventional flat panels. The knitting process for these elements represents a bottleneck in footwear production because flat-knitting machines must knit the uppers individually, which limits production capacity. This study explores ways to optimize knitting processes for 3D uppers. The focus is on reducing production time while maintaining product quality, ensuring a precise fit, and minimizing material waste. A series of experiments conducted on a base sneaker model implemented techniques to streamline knitting operations. These techniques were later adapted to other footwear types, including ankle boots, loafers, and sandals, to meet the unique requirements of each design. These optimizations include replacing traditional operations, such as overlocking or stitch decreases, with more efficient methods, such as open loops, as well as eliminating costly-to-manufacture elements. The results show significant reductions in production time while maintaining the fit and functional integrity of the uppers. These findings demonstrate both the technical feasibility and economic impact of these optimizations, offering valuable insights for the large-scale adoption of knitting technology in the footwear industry.
Published Version
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