Parametric design and process parameter optimization for bra cup molding via response surface methodology

Long Wu, Kit Lun Yick, Sun Pui Ng, Yiu Wan Yip, Kang Hoi Kong

Research output: Journal article publicationJournal articleAcademic researchpeer-review

21 Citations (Scopus)


Seamless and traceless undergarments have rendered foam sheet molding as an important manufacturing technique for the intimate apparel industry. Seamless bra cups are made by one-step forming technology. The three-dimensional (3D) cup shape is formed by using high temperatures and pressures with flexible polyurethane foams. Nevertheless, the mold head design process and control of the bra cup molding process are highly complicated and error prone. There is limited knowledge about the effects of foam properties, molding parameters and foam cup geometric parameters on molding process optimization. This research presents a response surface methodology as the approach for parametric design and process parameter optimization of bra cup molding. The proposed approach integrates 3D scanning via reverse engineering, parameterized-based remeshing and registration algorithm, non-linear mathematical prediction models for cup shape conformity, a model of foam shrinkage and example-based bra cup design and grading to optimize the bra cup development and production process. The experimental results show that this method is highly effective and more timesaving in the design and development of new products, as well as providing consistent quality control of the bra cup molding process.
Original languageEnglish
Pages (from-to)162-171
Number of pages10
JournalExpert Systems with Applications
Issue number1
Publication statusPublished - 1 Jan 2012


  • Bra cup molding
  • Parametric design
  • Polyurethane foam
  • Shrinkage
  • Thermal conductivity

ASJC Scopus subject areas

  • General Engineering
  • Computer Science Applications
  • Artificial Intelligence


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