Overview: For the past year I've been working on integrating sensors into knitted structures. This involves advanced lamination and adhesive methods so that the integration of sensors is done without losing the intrinsic flexibility and comfort of the textile.
Key Responsibilities:
Prototyping and Documentation: Documenting and refining prototypes to make sure that they conform to design specifications and tracking iterative improvements both in terms of function and aesthetics.
Cross-Functional Collaboration: I collaborate closely across disciplines including Mechanical, Electrical, Product Design, Industrial Design, Software Sensing and Tracking teams to make production easier while, at the same time, adding functionality in a way that maintains textiles inherent values while managing more rigid tolerances.
Project Coordination: Coordination of logistics and communication with teams, aligning prototype features with expectations and goals.
Material Library Maintenance: Maintain a range of textile material libraries, including technical specifications and testing data to help facilitate the selection of suitable materials.
Version Control Management: Version control for the development of systems to ensure that all team members have the latest data so that we may work efficiently and effectively.
Technical Skills and Innovations:
3D Knitting and Material Expertise: Experience working with many types of yarns and understand the knit sequencing needed to achieve desired mechanical and aesthetic properties.
Measurement Precision: I keep detailed documentation of every design iteration to be up to date on the evolution of the prototypes, such that each change can be captured for reference in the future.
Techniques and Innovations:
Knit Development: The past year has expanded my experience in knit development to include managing complex knit techniques, including the use of inlays, pointelle patterns, and bed transfers. I've since learned the nuances of needle gauges, loop lengths, and yarn behaviors, such as steaming and scaling, to enhance textile quality and durability.
Prototyping and Documentation: Documenting and refining prototypes to make sure that they conform to design specifications and tracking iterative improvements both in terms of function and aesthetics.
Cross-Functional Collaboration: I collaborate closely across disciplines including Mechanical, Electrical, Product Design, Industrial Design, Software Sensing and Tracking teams to make production easier while, at the same time, adding functionality in a way that maintains textiles inherent values while managing more rigid tolerances.
Project Coordination: Coordination of logistics and communication with teams, aligning prototype features with expectations and goals.
Material Library Maintenance: Maintain a range of textile material libraries, including technical specifications and testing data to help facilitate the selection of suitable materials.
Version Control Management: Version control for the development of systems to ensure that all team members have the latest data so that we may work efficiently and effectively.
Technical Skills and Innovations:
3D Knitting and Material Expertise: Experience working with many types of yarns and understand the knit sequencing needed to achieve desired mechanical and aesthetic properties.
Measurement Precision: I keep detailed documentation of every design iteration to be up to date on the evolution of the prototypes, such that each change can be captured for reference in the future.
Techniques and Innovations:
Knit Development: The past year has expanded my experience in knit development to include managing complex knit techniques, including the use of inlays, pointelle patterns, and bed transfers. I've since learned the nuances of needle gauges, loop lengths, and yarn behaviors, such as steaming and scaling, to enhance textile quality and durability.
Challenges and Problem Solving:
Testing for Integration Effects: Conduct extensive testing to understand how different methods of sensor integration impact the stretch and recovery of knitted fabrics. This involves evaluating various stack-ups of materials and sensors to find the optimal balance to maintain fabric performance.
Optimizing Sensor Functionality: Address challenges related to sensor functionality being affected by fabric distortion or flexing. Solutions often involve iterative redesigns of the sensor to align with areas of the material that experience minimal distortion.
Technical Skills and Material Expertise:
Material Compatibility: Extensive knowledge of textile properties ensures the selection of appropriate adhesives and laminates that are compatible with both the sensors and the base yarn, preventing degradation over time and with wear.
Precision Fabrication: Utilize precision assembly techniques to ensure sensors are accurately positioned according to design specifications, which is critical for the functionality of wearable technology.
Outcomes and Impact: Over 500 prototypes were developed and tested throughout my time, with more than 100 delivered to internal customers! The team went through a rigorous and iterative development process in knit technology for DV and EV builds, constantly improving techniques and solutions to meet the challenging requirements. The heavy prototyping was critical in getting advanced, operational systems out to contributors for the research and development of VR and AR.
Reflections: While focusing on knit development, I've significantly deepened my understanding of textiles, particularly in terms of their mechanical properties and the complex calculations necessary for their effective application. This progression was driven by a deeper need to understand material science, which enhanced my ability to understand how different fibers and their construction respond under various conditions. This experience has greatly improved my ability to integrate technical precision with creative textile applications, and has solidified my expertise in creating textiles that meet both aesthetic and functional demands.
Disclaimer:
Due to the confidential nature of this project and the terms of non-disclosure agreements, visual materials cannot be shared at this time.