Periodic Reporting for period 1 - NbyN (The New Generation Needle by Needle Knitting Machine)
Période du rapport: 2023-10-01 au 2024-09-30
The textile industry, particularly knitting, is on the brink of a significant transformation similar to the shift from offset printing to digital printing in the publishing world. Traditional knitting machines rely on mechanical cams to move needles along predefined routes, which inherently limits flexibility, speed, and efficiency. This conventional approach constrains manufacturers to large batch sizes and repetitive designs, often leading to excess inventory and waste. In an industry increasingly driven by demand for customization, sustainability, and rapid response to market trends, the limitations of current technology are becoming a significant bottleneck.
Our project, centered on the development and commercialization of the NbyN (Needle-by-Needle) technology, directly addresses these challenges. By integrating stepper motors to control each needle individually, the NbyN technology replaces mechanical cams, enabling unprecedented flexibility in design and production. This innovation allows for the creation of diverse patterns, styles, and sizes within a single production run, without the need for reconfiguration, thereby drastically reducing lead times and material waste. The NbyN technology promises to revolutionize not just the efficiency of production, but also the entire business model of knitting, supporting on-demand manufacturing and mass customization.
The overall objective of our project is to finalize the development of this groundbreaking NbyN technology and successfully bring it to market. This involves refining our prototype to a fully operational, market-ready machine, and validating its performance in real-world settings (reaching Technology Readiness Level 8). Our immediate goal is to enhance a circular knitting machine for hosiery with the NbyN technology, which will serve as the market entry point. Following successful commercialization, the technology will be adapted to other types of knitting machines, further expanding its impact across the textile industry.
The project is strategically positioned within the broader industry trend towards digitization and flexible manufacturing. By enabling a shift from mass production to mass customization, NbyN technology will empower manufacturers to better meet consumer demands, reduce environmental impact through more efficient resource use, and ultimately increase profitability. Our project's pathway to impact includes not only the technical development and commercialization of the NbyN technology but also the strategic partnerships and market readiness activities essential for successful uptake. Through collaborations with global distributors and key industry players, we have laid the groundwork for a swift and effective market launch. Additionally, our engagement with end-users and pilot partners ensures that the NbyN technology is rigorously tested and refined to meet the real-world demands of the industry.
Our project, centered on the development and commercialization of the NbyN (Needle-by-Needle) technology, directly addresses these challenges. By integrating stepper motors to control each needle individually, the NbyN technology replaces mechanical cams, enabling unprecedented flexibility in design and production. This innovation allows for the creation of diverse patterns, styles, and sizes within a single production run, without the need for reconfiguration, thereby drastically reducing lead times and material waste. The NbyN technology promises to revolutionize not just the efficiency of production, but also the entire business model of knitting, supporting on-demand manufacturing and mass customization.
The overall objective of our project is to finalize the development of this groundbreaking NbyN technology and successfully bring it to market. This involves refining our prototype to a fully operational, market-ready machine, and validating its performance in real-world settings (reaching Technology Readiness Level 8). Our immediate goal is to enhance a circular knitting machine for hosiery with the NbyN technology, which will serve as the market entry point. Following successful commercialization, the technology will be adapted to other types of knitting machines, further expanding its impact across the textile industry.
The project is strategically positioned within the broader industry trend towards digitization and flexible manufacturing. By enabling a shift from mass production to mass customization, NbyN technology will empower manufacturers to better meet consumer demands, reduce environmental impact through more efficient resource use, and ultimately increase profitability. Our project's pathway to impact includes not only the technical development and commercialization of the NbyN technology but also the strategic partnerships and market readiness activities essential for successful uptake. Through collaborations with global distributors and key industry players, we have laid the groundwork for a swift and effective market launch. Additionally, our engagement with end-users and pilot partners ensures that the NbyN technology is rigorously tested and refined to meet the real-world demands of the industry.
The NbyN project has made substantial progress in advancing the knitting industry through the development of a cutting-edge, Needle-by-Needle (NbyN) technology. This innovation replaces the traditional mechanical cams used in knitting machines with stepper motors that control each needle individually. Our work to date has focused on the meticulous design, engineering, and manufacturing of the NbyN-enhanced circular knitting machine, which promises to revolutionize the way knitting is performed.
Our initial efforts were dedicated to the comprehensive design of the machine and its components. This included developing CAD models and technical drawings for every part of the machine, ensuring that each element met the requirements for mass production. Particular attention was given to the mechanical structure of the knitting machine head, which includes the needles, each operated by a miniature stepper motor. Additional components, such as levers, cylinders, plate parts, yarn finger guides, sinker covers, and hooks, were meticulously designed to integrate seamlessly with the new technology. Following the design phase, we successfully manufactured all components. The production process included the fabrication of needles, levers, and hooks, as well as the creation the complete cylinder, yarn finger guides, sinker covers, frames, basement groups, and plate parts. Each component was produced with precision to ensure compatibility and optimal performance within the overall system. We have also identified the electrical components and purchased them.
With the design and manufacturing phases completed, the project is now ready to enter the assembly stage. The upcoming work involves integrating the mechanical and electrical components into a fully operational prototype. This prototype will serve as the first complete demonstration of the NbyN technology in a real-world setting. The assembly process will be followed by testing and demonstration activities to validate the machine’s performance and prepare it for market entry.
Our initial efforts were dedicated to the comprehensive design of the machine and its components. This included developing CAD models and technical drawings for every part of the machine, ensuring that each element met the requirements for mass production. Particular attention was given to the mechanical structure of the knitting machine head, which includes the needles, each operated by a miniature stepper motor. Additional components, such as levers, cylinders, plate parts, yarn finger guides, sinker covers, and hooks, were meticulously designed to integrate seamlessly with the new technology. Following the design phase, we successfully manufactured all components. The production process included the fabrication of needles, levers, and hooks, as well as the creation the complete cylinder, yarn finger guides, sinker covers, frames, basement groups, and plate parts. Each component was produced with precision to ensure compatibility and optimal performance within the overall system. We have also identified the electrical components and purchased them.
With the design and manufacturing phases completed, the project is now ready to enter the assembly stage. The upcoming work involves integrating the mechanical and electrical components into a fully operational prototype. This prototype will serve as the first complete demonstration of the NbyN technology in a real-world setting. The assembly process will be followed by testing and demonstration activities to validate the machine’s performance and prepare it for market entry.
The NbyN technology represents a significant advancement over traditional knitting methods, introducing unprecedented flexibility and efficiency by enabling individual needle control through stepper motors. This innovation allows for the production of diverse patterns and designs in a single production run without the need for reconfiguration, reducing lead times, waste, and costs. The potential impacts include:
Enhanced Production Flexibility: The ability to create customized designs on demand, supporting mass customization and responsive manufacturing.
Economic Impact: Significant revenue within three years of market entry for us and our partners, driven by the commercialization of the NbyN technology.
Environmental Benefits: Reduction in waste and overproduction through more efficient, on-demand manufacturing.
Enhanced Production Flexibility: The ability to create customized designs on demand, supporting mass customization and responsive manufacturing.
Economic Impact: Significant revenue within three years of market entry for us and our partners, driven by the commercialization of the NbyN technology.
Environmental Benefits: Reduction in waste and overproduction through more efficient, on-demand manufacturing.