Description:1
FORM 2
THE PATENT ACT 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule13)
1.
TITLE OF THE INVENTION
SYSTEM AND METHOD FOR DIGITALLY INTEGRATED, JUST-IN-TIME GARMENT MANUFACTURING
2.
APPLICANT (S)
Name: IBA CRAFTS PVT. LTD.
Address: E-17, Sector-11, Noida, Uttarpradesh-201301
Nationality: India
3.
PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner
in which it is to be performed.
2
SYSTEM AND METHOD FOR DIGITALLY INTEGRATED, JUST-IN-TIME GARMENT MANUFACTURING
TECHNICAL FIELD
[0001]
The present invention relates to manufacturing, in particular to a system and method for digitally integrated, just-in-time garment manufacturing with 48-hour order fulfilment for rapid, on-demand fashion production that minimizes inventory waste, environmental impact, and production inefficiencies in commercial, fast-fashion, digital retail, corporate merchandising, and specialty apparel applications.
BACKGROUND
[0002]
Rapidly evolving consumer expectations in the apparel sector have created a pressing need to address inefficiencies in conventional production methods. In particular, manufacturers face challenges in meeting the demand for timely delivery and customization in a market that increasingly favors agile, on-demand processes over traditional bulk production. This technical field, which encompasses commercial apparel manufacturing and digital textile processing, urgently requires efficient production scheduling and inventory management to keep pace with dynamic market trends.
[0003]
Presently, the art predominantly relies on established methods that utilize batch production and large-scale inventory stocking. Existing systems attempt to manage production through print-on-demand technologies at the fabric level and conventional production lines in apparel manufacturing. These solutions generally involve predetermined schedules and manual coordination, which aim to streamline production but often result in operational delays and high inventory levels.
[0004]
Notwithstanding the advances in print-on-demand and automation technologies, these conventional methods exhibit significant limitations. They are burdened by inherent inefficiencies such as overproduction, leading to unsold inventory and the consequent tying up of capital. Additionally, the approach is marked by the excessive consumption of resources, including water, energy, and raw materials, thereby raising sustainability concerns. Further shortcomings include production inflexibility and labor-related issues stemming from manual interventions that compromise quality control and timely processing.
3
[0005]
In view of the deficiencies identified in existing manufacturing processes, there is a clear technical need for a more efficient and responsive system for digitally integrated, just-in-time garment manufacturing.
[0006]
Further limitations and disadvantages of conventional approaches will become apparent to one of skill in the art through the comparison of the described systems with some aspects of the present disclosure, as outlined in the remainder of the present application and regarding the drawings. In some embodiments, the numbers expressing quantities or dimensions of items, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.”
4
SUMMARY OF THE INVENTION
[0007]
The present invention mainly solves the technical problems existing in the prior art. In response to these problems, the present invention provides a system and method for digitally integrated, just-in-time garment manufacturing.
[0008]
An aspect of the present disclosure relates to an integrated garment manufacturing system for digitally integrated, just-in-time garment manufacturing. The system includes a computing device, a fabric pre-processing unit, a digital textile printing subsystem, a customized cutting subsystem, a timer-linked tailor workstation, and a quality control and dispatch subsystem. The fabric pre-processing unit is configured to subject a white or greige fabric to controlled washing, sizing, and coating procedures for conditioning the fabric and modifying surface energy. The digital textile printing subsystem is configured to receive pre-processed fabric and digital job ticket data to apply a desired design onto designated garment panel areas via a precision printing head. The customized cutting subsystem includes a modified cutting bed and a non-contact laser cutting mechanism configured to receive SKU-linked graded patterns from the digital order orchestration controller and execute cutting operations with precision path planning and controlled energy delivery. The timer-linked tailor workstation is configured to receive a set of cut fabric panels and convert digitally generated graded patterns into stitching instructions, comprising a built-in timer that records assembly cycle times. The quality control and dispatch subsystem is configured to inspect assembled garments using a set of automated inspection tools and a set of digital checklists and to affix a machine-readable identifier upon successful inspection.
[0009]
The computing device includes a processor, a memory, a communication interface, a digital order orchestration controller, a color management module, and a traceability and genealogy module. The processor is operable to execute one or more routines pertaining to garment manufacturing. The memory is configured to store the one or more routines executed by the processor. The digital order orchestration controller is configured to capture customer orders from an online interface and convert each order into a digital job ticket comprising: design, color, size, and fabric requirements. The color management module includes an International Color Consortium (ICC) profile library and a raster image processor (RIP) configured to select and apply a fabric-specific ICC profile to the fabric during a digital printing process. The color management module controls ink
5
flow, color balance, and reproduction to adhere to a color difference threshold. The traceability and genealogy module is configured to record in a database a set of production parameters corresponding to each stage of manufacturing from fabric pre-processing through one or more of: printing, cutting, tailoring, and quality control.
[0010]
In an embodiment, the fabric pre-processing unit further includes an environmental control equipment configured to regulate temperature, humidity, and chemical dosages, and one or more quality check stations configured to log the processed fabric into the centralized genealogy record.
[0011]
In an embodiment, the digital order orchestration controller includes a set of modules configured to capture design inputs, fabric specifications, color specifications, and size specifications from multiple endpoints, and to communicate corresponding graded patterns to a digital textile printing subsystem and a customized cutting subsystem.
[0012]
In an embodiment, the color management module is further configured to interact with the raster image processor (RIP) to dynamically adjust a set of printing parameters in accordance with the fabric type specified in the digital job ticket.
[0013]
In an embodiment, the digital textile printing subsystem includes a precision printing head and associated guidance mechanisms for controlled ink application on designated garment panel areas as dictated by the digital job ticket.
[0014]
In an embodiment, the customized cutting subsystem further includes an assist-air delivery means configured to modulate a non-contact laser cutting mechanism for executing edge-integrity cuts with maintained dimensional tolerances of ±1 mm.
[0015]
In an embodiment, the timer-linked tailor workstation includes a mobile client device configured to display stitching instructions derived from the graded pattern and to initiate a local timer that records real-time assembly metrics.
[0016]
In an embodiment, the automated inspection tools are used to verify print quality, stitching accuracy, and conformity to the digital job ticket, and further include a means for affixing a machine-readable identifier, such as a QR code or NFC tag, to each finished garment.
6
[0017]
In an embodiment, the traceability and genealogy module is configured to continuously aggregate production data, includes a set of parameters received from the fabric pre-processing unit, the digital order orchestration controller, the color management module, the digital textile printing subsystem, the customized cutting subsystem, the timer-linked tailor workstation, and the quality control and dispatch subsystem to generating a comprehensive digital record for each garment manufactured.
[0018]
Another aspect of the present disclosure relates to a method for digitally integrated, just-in-time garment manufacturing. The method includes a step of pre-processing a white or greige fabric by subjecting the fabric to controlled washing, sizing, and coating procedures to modify surface energy. The method includes a step of capturing a customer order through an online interface and converting the order into a digital job ticket, including design, fabric, color, and size information. The method includes a step of selecting and applying a fabric-specific ICC profile via a color management module integrated with a raster image processor (RIP) to control ink flow and color balance during printing. The method includes a step of digitally printing the design onto designated garment panel areas of the pre-processed fabric using a digital textile printing subsystem. The method includes a step of cutting the printed fabric panels using a customized cutting subsystem that employs a non-contact laser cutting mechanism guided by SKU-linked graded patterns. The method includes a step of transferring the cut fabric panels to a timer-linked tailor workstation. The digitally generated stitching instructions are executed with a built-in timer that records cycle times. The method includes a step of inspecting the assembled garment using automated quality control measures and affixing a machine-readable identifier upon conformance. The method includes a step of recording a set of production parameters from the pre-processing, order orchestration, printing, cutting, tailoring, and quality control steps into a centralized traceability database.
[0019]
Accordingly, one object of the present invention is to provide a fully integrated, just-in-time manufacturing system that transitions traditional batch production into a single-piece flow, thereby eliminating the excess inventory and capital lock-in associated with conventional production methods.
[0020]
Accordingly, another object of the present invention is to provide a method for pre-processing base fabrics by employing controlled chemical and mechanical treatments, including washing, sizing, and coating, to render white or grey fabrics optimally receptive
7
to subsequent printing, dyeing, or embroidery, thus achieving enhanced adhesion, ink absorption, and rapid turnaround without compromising quality.
[0021]
Accordingly, another object of the present invention is to provide a digital printing system integrating ICC-profile management and a Raster Image Processing (RIP) interface that maintains per-fabric color profiles to achieve strict ΔE thresholds, thereby ensuring consistent, high-fidelity color reproduction across diverse fabric types.
[0022]
Accordingly, another object of the present invention is to provide customized cutting machinery incorporating a modified cutting bed and a non-contact laser cutting mechanism, which leverages precise energy delivery and controlled process parameters to achieve an edge-integrity cut with minimal heat-affected zones and a dimensional tolerance of approximately ±1 mm.
[0023]
Accordingly, another object of the present invention is to provide an enhanced sewing operation wherein tailor stations are digitally integrated with a timer-enforced workflow system that converts digital job tickets into precise stitching instructions, ensuring labor efficiency, consistency in production cycle times, and comprehensive traceability of each garment.
[0024]
Accordingly, another object of the present invention is to provide a holistic digital workflow and order orchestration controller that links all stages from fabric pre-processing to printing, cutting, sewing, and dispatch in a single, real-time monitored production chain, thereby optimizing sequence timing, minimizing bottlenecks, and improving overall operational efficiency.
[0025]
Accordingly, another object of the present invention is to provide a comprehensive traceability system that embeds machine-readable identifiers and detailed genealogy records, including machine parameters, operator data, and quality control metrics throughout the production process to enhance accountability, prevent counterfeiting, and support reliable returns adjudication.
[0026]
Accordingly, one object of the present invention is to provide an environmentally sustainable manufacturing method by fabricating garments on demand, thereby reducing water, energy, and raw material usage while minimizing production waste and overproduction associated with traditional bulk manufacturing processes.
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[0027]
Accordingly, one object of the present invention is to provide a scalable and adaptable production platform capable of efficiently managing thousands of stock-keeping units (SKUs) for diverse applications such as fashion brands, corporate merchandising, and marketplaces, ensuring rapid response to market trends and individual design preferences.
[0028]
Other features of embodiments of the present disclosure will be apparent from the accompanying drawings and from the detailed description that follows.
[0029]
Yet other objects and advantages of the present invention will become readily apparent to those skilled in the art following the detailed description, wherein the preferred embodiments of the invention are shown and described, simply by way of illustration of the best mode contemplated herein for carrying out the invention. As we realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawings and description thereof are to be regarded as illustrative in nature and not as restrictive.
9
BRIEF DESCRIPTION OF THE DRAWINGS
[0030]
In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description applies to any one of the similar components having the same first reference label, irrespective of the second reference label.
[0031]
FIG. 1 illustrates a network implementation of a system for digitally integrated, just-in-time garment manufacturing, in accordance with an embodiment of the present subject matter.
[0032]
FIG. 2 illustrates a block diagram of various components of the computing device of the present system, in accordance with an embodiment of the present subject matter.
[0033]
FIG. 3 illustrates an operational flow diagram of the present system, in accordance with an embodiment of the present subject matter.
[0034]
FIG. 4 illustrates a user interface related to a digital tracking dashboard, in accordance with an embodiment of the present subject matter.
[0035]
FIG. 5 illustrates a user interface related to an order status, in accordance with an embodiment of the present subject matter.
[0036]
FIG. 6 illustrates a machine SKU selection user interface, in accordance with an embodiment of the present subject matter.
[0037]
FIG. 7 illustrates a flowchart of a method for digitally integrated, just-in-time garment manufacturing, in accordance with an embodiment of the present subject matter.
[0038]
FIG. 8 illustrates a perspective view of a customized CNC laser cutting machine with an extended bed, in accordance with an embodiment of the present subject matter.
10
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0039]
The present disclosure is best understood with reference to the detailed figures and description set forth herein. Various embodiments have been discussed with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions provided herein with respect to the figures are merely for explanatory purposes, as the methods and systems may extend beyond the described embodiments. For instance, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond certain implementation choices in the following embodiments.
[0040]
The present disclosure relates to systems and methods for orchestrating the execution of complex tasks. Rather than relying on a single monolithic AI model, the present system employs a centralized orchestration controller that dynamically decomposes a user query into sub-tasks, assigns those sub-tasks to specialized agent modules based on their capabilities, and aggregates the outputs to generate a coherent final response. This architecture allows for the flexible integration of task-specific agents, such as a research agent, analysis agent, or responder agent, and enables runtime routing of sub-tasks via a functionally adaptive orchestration layer. The role-based agent design is reusable and extensible, allowing the orchestration pattern to be abstracted and applied across diverse domains by simply plugging in relevant tools and agents. The present system and method provide a generalized framework for orchestrating intelligent task workflows in AI systems.
[0041]
Embodiments of the present disclosure may be provided as a computer program product, which may include a machine-readable storage medium tangibly embodying thereon instructions, which may be used to program a computer (or other electronic devices) to perform a process. The machine-readable medium may include, but is not limited to, fixed (hard) drives, magnetic tape, floppy diskettes, optical disks, compact disc read-only memories (CD-ROMs), and magneto-optical disks, semiconductor memories, such as ROMs, PROMs, random access memories (RAMs), programmable read-only memories (PROMs), erasable PROMs (EPROMs), electrically erasable PROMs (EEPROMs), flash memory, magnetic or optical cards, or other types of media/machine-
11
readable medium suitable for storing electronic instructions (e.g., computer programming code, such as software or firmware).
[0042]
Various methods described herein may be practiced by combining one or more machine-readable storage media containing the code according to the present disclosure with appropriate standard computer hardware to execute the code contained therein. An apparatus for practicing various embodiments of the present disclosure may involve one or more computers (or one or more processors within a single computer) and storage systems containing or having network access to a computer program(s) coded in accordance with various methods described herein, and the method steps of the disclosure could be accomplished by modules, routines, subroutines, or subparts of a computer program product.
[0043]
The term “machine-readable storage medium” or “computer-readable storage medium” includes, but is not limited to, portable or non-portable storage devices, optical storage devices, and various other mediums capable of storing, containing, or carrying instruction(s) and/or data. A machine-readable medium may include a non-transitory medium in which data can be stored, and that does not include carrier waves and/or transitory electronic signals propagating wirelessly or over wired connections. Examples of a non-transitory medium may include, but are not limited to, a magnetic disk or tape, optical storage media such as compact disk (CD) or versatile digital disk (DVD), flash memory, or memory devices.
[0044]
A system for just-in-time garment manufacturing is provided that transitions traditional batch production into a single-piece, on-demand production paradigm. The invention comprises a series of digitally integrated components that collectively enable rapid order processing, quality-assured fabrication, and environmentally efficient production. The invention utilizes digital manufacturing control, material science, precision mechanics, and real-time process integration to create a seamless manufacturing ecosystem where each order is rendered into a digital job ticket and processed through customized pre-processing, printing, cutting, and assembling operations.
[0045]
The system accommodates a plurality of orders by converting each customer input into a corresponding job ticket that details design, color, size, and fabric requirements. This approach enables each production stage to execute predetermined tasks in a
12
controlled environment. A key novel feature of the invention is the precise conditioning of white or greige fabric, which undergoes chemical and mechanical pre-processing through washing, sizing, and coating.
[0046]
FIG. 1 illustrates a network implementation of a system 100 for digitally integrated, just-in-time garment manufacturing, in accordance with an embodiment of the present subject matter. The system 100 includes a database 103, an application server 105, a network 107, a computing device 109, a fabric pre-processing unit 12, a digital textile printing subsystem 18, a customized cutting subsystem 20, a timer-linked tailor workstation 22, and a quality control and dispatch subsystem 24. Although the present subject matter is explained considering that the present system 100 is implemented on the application server 105, it may be understood that the present system 100 may also be implemented in a variety of computing systems, such as a laptop computer, a desktop computer, a notebook, a workstation, a mainframe computer, a server, a network server, or a cloud-enabled orchestration layer or equivalent infrastructure configured for order routing, storage, and visualization. It will be understood that the present system 100 may be accessed by multiple users through multiple computing devices 109. Examples of computing devices 109 may include, but are not limited to, a portable computer, a personal digital assistant, a handheld or mobile device, smart devices, workstations, smartphones, laptops, and tablets. The computing devices 109 are communicatively accessible to the system 100 through the network 107.
[0047]
The fabric pre-processing unit 12 is configured to subject a white or greige fabric to controlled washing, sizing, and coating procedures for conditioning the fabric and modifying surface energy. The digital textile printing subsystem 18 is configured to receive pre-processed fabric and digital job ticket data to apply a desired design onto designated garment panel areas via a precision printing head. The customized cutting subsystem 20 includes a modified cutting bed and a non-contact laser cutting mechanism configured to receive SKU-linked graded patterns from the digital order orchestration controller and execute cutting operations with precision path planning and controlled energy delivery. The timer-linked tailor workstation 22 is configured to receive a set of cut fabric panels and convert digitally generated graded patterns into stitching instructions, comprising a built-in timer that records assembly cycle times. The quality control and dispatch subsystem 24 is configured to inspect assembled garments using a
13
set of automated inspection tools and a set of digital checklists and to affix a machine-readable identifier upon successful inspection.
[0048]
In an embodiment, the fabric pre-processing unit 12 further includes an environmental control equipment configured to regulate temperature, humidity, and chemical dosages, and one or more quality check stations configured to log the processed fabric into the centralized genealogy record. In an embodiment, the digital textile printing subsystem 18 includes a precision printing head and associated guidance mechanisms for controlled ink application on designated garment panel areas as dictated by the digital job ticket. In an embodiment, the customized cutting subsystem 20 further includes an assist-air delivery means configured to modulate a non-contact laser cutting mechanism for executing edge-integrity cuts with maintained dimensional tolerances of ±1 mm. In an embodiment, the timer-linked tailor workstation 22 includes a mobile client device configured to display stitching instructions derived from the graded pattern and to initiate a local timer that records real-time assembly metrics. In an embodiment, the automated inspection tools are used to verify print quality, stitching accuracy, and conformity to the digital job ticket, and further include a means for affixing a machine-readable identifier, such as a QR code or NFC tag, to each finished garment.
[0049]
The database 103 is configured to store external data and metadata associated with the garment manufacturing. In an embodiment, the database 103, the application server 105, and the computing device 109 are connected over the network 107.
[0050]
In one implementation, the network 107 may correspond to a communication medium through which the application server 105, and one or more computing devices 109 may communicate with each other. Such communication may be performed in accordance with various wired and wireless communication protocols. Examples of such wired and wireless communication protocols include, but are not limited to, Transmission Control Protocol and Internet Protocol (TCP/IP), User Datagram Protocol (UDP), Hypertext Transfer Protocol (HTTP), File Transfer Protocol (FTP), ZigBee, EDGE, infrared (IR), IEEE 802.11, 802.16, 2G, 3G, 4G cellular communication protocols, and/or Bluetooth (BT) communication protocols. Network 107 may include, but is not limited to, the Internet, a cloud network, a Wireless Fidelity (Wi-Fi) network, a Wireless Local Area Network (WLAN), a Local Area Network (LAN), a telephone line (POTS), and/or a Metropolitan Area Network (MAN).
14
[0051]
In an embodiment, the application server 105 may refer to a computing device or a software framework hosting an application or a software service. In an embodiment, the application server 105 may be implemented to execute procedures such as, but not limited to, programs, routines, or scripts stored in one or more memories for supporting the hosted application or the software service. In an embodiment, the hosted application or the software service may be configured to perform one or more predetermined operations. The application server 105 may be realized through various types of application servers, such as, but are not limited to, a .NET framework application server, a Base4 application server, a PHP framework application server, or any other application server framework. In an embodiment, the application server 102 may be realized as an application program installed on and/or running on one or more computing devices 109 without departing from the scope of the disclosure.
[0052]
In some embodiments, system 100 may be the application server 105 and therefore may be co-located. For example, system 100 may be embodied as a cloud-based service, a cloud-based application, a cloud-based platform, a remote server-based service, a remote server-based application, a remote server-based platform, or a virtual computing system. The application server 105 may comprise one or more processors configured to process requests received from the computing device 109.
[0053]
FIG. 2 illustrates a block diagram of various components of the computing device 109 of the present system 100, in accordance with an embodiment of the present subject matter. FIG. 2 is explained in conjunction with FIG. 1. The computing device 109 includes a processor 201, a memory 203, a communication interface 205, a digital order orchestration controller 14, a color management module 16, and a traceability and genealogy module 26. The processor 201 is operable to execute one or more routines pertaining to garment manufacturing. The memory 203 is configured to store the one or more routines executed by the processor 201.
[0054]
The communication interface 205 may provide an interface for accessing various features and data stored in the present system 100. For example, the communication interface 205 may comprise an I/O interface that may be in the form of a GUI, a touch interface, a voice-enabled interface, a keypad, and the like.
15
[0055]
Processor 201 may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, state machines, logic circuitries, and/or any devices that manipulate signals based on operational instructions. Among other capabilities, at least one processor 201 is configured to fetch and execute computer-readable instructions stored in the memory 203.
[0056]
The memory 203 is configured to store one or more routines executed by the processor. Memory 203 may include any computer-readable medium known in the art, including, for example, volatile memory, such as static random access memory (SRAM) and dynamic random access memory (DRAM), and/or non-volatile memory, such as read-only memory (ROM), erasable programmable ROM, flash memories, hard disks, optical disks, and magnetic tapes. Modules include routines, programs, objects, components, data structures, etc., which perform particular tasks or implement particular abstract data types.
[0057]
The digital order orchestration controller 14 is configured to capture customer orders from an online interface and convert each order into a digital job ticket comprising: design, color, size, and fabric requirements. The color management module 16 includes an International Color Consortium (ICC) profile library and a raster image processor (RIP) configured to select and apply a fabric-specific ICC profile to the fabric during a digital printing process. The color management module 16 controls ink flow, color balance, and reproduction to adhere to a color difference threshold. The traceability and genealogy module 26 is configured to record in the database 103 a set of production parameters corresponding to each stage of manufacturing from fabric pre-processing through one or more of: printing, cutting, tailoring, and quality control.
[0058]
In an embodiment, the digital order orchestration controller 14 includes a set of modules configured to capture design inputs, fabric specifications, color specifications, and size specifications from multiple endpoints, and to communicate corresponding graded patterns to a digital textile printing subsystem and a customized cutting subsystem.
[0059]
In an embodiment, the color management module 16 is further configured to interact with the raster image processor (RIP) to dynamically adjust a set of printing parameters in accordance with the fabric type specified in the digital job ticket.
16
[0060]
In an embodiment, the traceability and genealogy module 26 is configured to continuously aggregate production data, includes a set of parameters received from the fabric pre-processing unit 12, the digital order orchestration controller 14, the color management module 16, the digital textile printing subsystem 18, the customized cutting subsystem 20, the timer-linked tailor workstation 22, and the quality control and dispatch subsystem 24 to generating a comprehensive digital record for each garment manufactured.
[0061]
In operation, the fabric pre-processing unit 12 subjects the fabric to controlled treatment under regulated environmental conditions such as temperature, humidity, and chemical dosage. The treated base fabric exhibits uniform surface energy and enhanced receptivity to ink absorption and adhesion, thereby providing a print-ready substrate that achieves colorfastness and durability over a rapid processing period. The conditioned fabric is subsequently logged into a centralized genealogy record, ensuring traceability from the outset.
[0062]
Subsequent to fabric pre-processing, a digital order orchestration controller 14 captures orders from an online interface and converts these into digital job tickets. The order orchestration controller 14 is configured as a central processing unit that receives design inputs, fabric specifications, and graded pattern details from multiple endpoints. The controller then routes the information to the relevant production units and communicates with the digital printing subsystem 18 and customized cutting subsystem 20 using standardized, SKU-linked instructions. In one embodiment, the controller 14 bridges the digital workflow by passing measured parameters to precise downstream processes to ensure that production is executed in a just-in-time manner.
[0063]
The color management module 16 includes, but is not limited to, an International Color Consortium (ICC) profile library and a raster image processor (RIP). This module is configured to select a fabric-specific ICC profile based on the job ticket and to apply it at the time of printing. The color management module 16 dynamically adjusts ink flow, color balance, and reproduction parameters to adhere to a defined ΔE threshold. The system thereby ensures accurate color reproduction as dictated by principles of colorimetry and optical physics. The color management module 16 interacts directly with the digital textile printing subsystem 18 so that any variation in fabric type or environmental conditions can be compensated through real-time digital adjustments.
17
[0064]
The digital textile printing subsystem 18 is configured to receive pre-processed fabric directly from the fabric pre-processing unit 12 and to print designs onto designated garment panel areas. In one embodiment, the subsystem 18 includes a precision printing head and supportive guidance mechanisms that align the fabric accurately during the printing process to ensure that printed outputs adhere to the design geometry defined in the job ticket. The printing subsystem is further synchronized with the color management module 16 to maintain a consistent quality standard across different fabric types, whereby each printed panel exhibits uniform visual properties and meets the required ΔE threshold.
[0065]
The customized cutting subsystem 20 is provided immediately downstream of the digital textile printing subsystem 18. The customized cutting subsystem 20 incorporates a modified cutting bed and a non-contact laser cutting mechanism designed to receive SKU-linked graded patterns from the digital order orchestration controller 14. In one embodiment, the cutting bed comprises alignment features and hold-down mechanisms that secure the fabric, while the laser cutting head employs controlled energy delivery, assist-air means, and precise path planning to achieve edge-integrity cuts with dimensional tolerances maintained at approximately ±1 mm. The integration of assist-air delivery means and real-time calibration ensures that fabric panels are cut without melting or charring, preserving the structural and aesthetic properties of the material.
[0066]
Subsequent to the cutting process, cut fabric panels are transferred to a timer-linked tailor workstation 22. The tailor workstation 22 comprises mobile client devices that display digitally generated stitching instructions derived from the identical graded pattern used in the cutting stage. Each tailor workstation is linked to the digital order orchestration controller 14 such that upon scanning the unique job ticket, a built-in timer is initiated to record assembly cycle times. The timer data is stored as part of a comprehensive digital traceability record, which also logs operator details. This integration ensures that the assembly process is executed with precise cycle control and enables real-time monitoring of labor efficiency in accordance with lean manufacturing principles and time-motion studies.
[0067]
A quality control and dispatch subsystem 24 is then employed to inspect the assembled garments. The subsystem 24 includes automated inspection tools that verify printing accuracy, stitching quality, and overall conformance to the digital job ticket.
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Upon satisfactory completion of a digital checklist, the finished garment is affixed with a machine-readable identifier, such as a QR code or NFC tag, to ensure that each product is associated with its complete genealogy record. The subsystem 24 further integrates with the digital order orchestration controller 14 to trigger packaging and manage dispatch to ensure that the garment is shipped within the targeted 48-hour turnaround period.
[0068]
The traceability and genealogy module 26 is configured to aggregate production data from each stage of the manufacturing process. The module 26 records parameters produced by the fabric pre-processing unit 12, digital order orchestration controller 14, color management module 16, digital textile printing subsystem 18, customized cutting subsystem 20, and timer-linked tailor workstation 22, as well as quality control and dispatch data from the quality control subsystem 24. The resulting comprehensive record provides a detailed digital history for each garment manufactured, which facilitates returns adjudication, anti-counterfeit measures, and production optimization analyses.
[0069]
In one embodiment of the present invention, the production process commences with fabric pre-processing that prepares the substrate in a controlled manner. A subsequent digital order capture and job ticket generation stage ensures that production details are accurately conveyed to the color management module 16, where a per-fabric ICC profile is selected. The digital textile printing subsystem 18 then prints the design onto the pre-treated fabric according to a print-ready layout generated by the RIP, thereby ensuring that the visual output meets specific ΔE thresholds. Following an optional post-printing stabilization treatment, the pre-printed fabric is transferred to a customized cutting subsystem 20 where a non-contact laser cutter performs edge-integrity cuts with minimal material wastage. The resultant cut panels are immediately routed to timer-linked tailor workstations 22, where real-time assembly instructions enforce a production standard through built-in timers, thereby recording the efficiency of the tailoring operations.
[0070]
In one embodiment, the digital textile printing subsystem 18 is configured to print a SKU-specific barcode directly onto the fabric panel during the printing process. The printed barcode is designed to persist through subsequent fabric pre-processing steps, including washing, without degradation or loss of readability. At the cutting stage, the customized cutting subsystem 20 scans the barcode and automatically retrieves the corresponding cutting file, thereby eliminating mapping errors that may occur in micro-
19
batch production. This traceability ensures accurate alignment between printed designs and cutting patterns, enhancing operational efficiency and reducing manual intervention.
[0071]
In another embodiment, the fabric pre-processing unit 12 is configured to perform a controlled washing protocol on fabric lots comprising multiple parallel printed segments, each ranging from approximately 1 to 3 meters in length. The fabric lot may extend up to approximately 200 meters and include several unique printed designs processed together in a single batch. The washing protocol is optimized to prevent cross-color contamination between adjacent segments during the post-processing wash, thereby maintaining the integrity and color fidelity of each design throughout the production process. This enables efficient handling of micro-batches within larger fabric lots without compromising design quality.
[0072]
FIG. 3 illustrates an operational flow diagram 300 of the present system, in accordance with an embodiment of the present subject matter. An embodiment of the invention further provides a method for digitally integrated, just-in-time garment manufacturing. The method involves pre-processing a white or greige fabric by subjecting the material to controlled washing, sizing, and coating procedures that modify the surface for optimal ink receptivity. A customer order is then captured through an online interface and converted into a digital job ticket that integrates design, fabric, color, and size specifications. The selected per-fabric ICC profile is applied during a digitally controlled printing process, whereby the printed design is confined to specific garment panel areas. The printed fabric is subsequently post-processed to stabilize the print before being precisely cut using a non-contact laser cutting system guided by a SKU-linked graded pattern. The cut panels are assembled at a timer-linked tailor workstation, wherein the assembly process is monitored in real time and recorded. Automated quality control checks are executed via a quality control and dispatch subsystem that finalizes the production record by affixing a machine-readable identifier. All production parameters are logged into a centralized traceability database that supports both real-time analytics and future verification procedures.
[0073]
An embodiment of the present invention may incorporate modifications or alternative embodiments without departing from the scope of the invention. For instance, components such as the fabric pre-processing unit 12 or the timer-linked tailor workstation 22 may include additional sensors or machine vision systems to further
20
enhance precision and traceability. Similarly, variations in the laser cutting subsystem 20 may involve alternative energy modulation controls or registration aids to accommodate different fabric types and thicknesses. In other embodiments, the network connectivity between the digital order orchestration controller 14 and the downstream production units may be implemented using wireless technology, thereby enhancing flexibility and scalability. The present invention, therefore, embraces a plurality of variations that may include, but are not limited to, different material combinations, environmental control mechanisms, and digital communication protocols.
[0074]
FIG. 4 illustrates a user interface related to a digital tracking dashboard 400, in accordance with an embodiment of the present subject matter. The present invention introduces a complete manufacturing ecosystem that transforms a white or greige base garment fabric into a ready-to-wear commercial garment within 48 hours of order placement. The system incorporates customised base fabric pre-processing, wherein all base fabrics undergo controlled washing, sizing, and coating to ensure immediate readiness for printing, dyeing, or embroidery. This pre-processing step enhances colorfastness, enables vivid printing, and provides a long-lasting fabric finish comparable to traditional batch dyeing, while post-processing stabilises the fabric within 24 hours to enable instant cutting and sewing. The ecosystem further includes customised cutting and sewing machinery, wherein cutting machine beds and laser systems are adapted to match standard garment panel sizes, thereby improving precision and reducing fabric wastage. Tailor workstations are integrated with digital punch-in systems that activate real-time production timers to monitor efficiency and control costs. A digital workflow integration layer connects order sheets, tailor applications, and timer activations such that each order is digitally tracked from allocation through stitching completion, with a central dashboard providing live status updates for each garment and enabling immediate identification of bottlenecks. Through this integration, the invention enables a rapid turnaround time of 48 hours by seamlessly linking design selection, fabric processing, cutting, sewing, finishing, and packing without idle waiting periods. The system employs just-in-time (JIT) production principles to ensure that only sold pieces are manufactured, thereby eliminating stock-outs while preventing overproduction. Moreover, the present system is designed for scalability across B2B2C applications, enabling brands, retailers, and marketplaces to provide all designs and all sizes on demand without maintaining physical inventory.
21
[0075]
FIG. 5 illustrates a user interface 500 related to an order status, in accordance with an embodiment of the present subject matter. The order status interface depicts pending orders, sent for printing, sent for making, sent for knitting, sent for cutting, sent for OnHold, allotted, sent for finishing, dispatched, alteration, and fabric issues. The detailed process flow of the present invention begins with order placement, wherein a customer selects a desired design, size, and color through an online interface. Upon confirmation, the system captures the digital order and generates a corresponding job ticket that is allocated for production. Fabric pre-processing is carried out in advance for all base stocks, including cleaning, sizing, and coating operations, to ensure immediate readiness for printing, dyeing, or embroidery. Once an order is placed, printing, dyeing, or embroidery of the pre-processed fabric is executed within a few hours. Thereafter, customised cutting is performed using modified cutting bed machines that enable precise panel cutting with minimal wastage. The sewing stage is carried out by tailors operating through a timer-tracked application that monitors stitching progress against predefined benchmark hours.
[0076]
FIG. 6 illustrates a machine SKU selection user interface 600, in accordance with an embodiment of the present subject matter. Following sewing, the garments undergo finishing and quality control processes, including pressing, labelling, and packing. Lastly, the completed garments are dispatched and made ready for shipment within 48 hours of order placement. A user may use the machine SKU and order ID interface to enter the machine number, order number, and SKU to get the required details.
[0077]
FIG. 7 illustrates a flowchart of a method 700 for digitally integrated, just-in-time garment manufacturing, in accordance with an embodiment of the present subject matter. The method 700 includes a step 701 of pre-processing a white or greige fabric by subjecting the fabric to controlled washing, sizing, and coating procedures to modify surface energy. The method 700 includes a step 703 of capturing a customer order through an online interface and converting the order into a digital job ticket, including design, fabric, color, and size information. The method 700 includes a step 705 of selecting and applying a fabric-specific ICC profile via a color management module integrated with a raster image processor (RIP) to control ink flow and color balance during printing. The method 700 includes a step 707 of digitally printing the design onto designated garment panel areas of the pre-processed fabric using a digital textile printing
22
subsystem. The method 700 includes a step 709 of cutting the printed fabric panels using a customized cutting subsystem that employs a non-contact laser cutting mechanism guided by SKU-linked graded patterns. The method 700 includes a step 711 of transferring the cut fabric panels to a timer-linked tailor workstation. The digitally generated stitching instructions are executed with a built-in timer that records cycle times. The method 700 includes a step 713 of inspecting the assembled garment using automated quality control measures and affixing a machine-readable identifier upon conformance. The method 700 includes a step 715 of recording a set of production parameters from the pre-processing, order orchestration, printing, cutting, tailoring, and quality control steps into a centralized traceability database.
[0078]
FIG. 8 illustrates a perspective view of a customized CNC laser cutting machine 20 with an extended bed, in accordance with an embodiment of the present subject matter. In an embodiment, the customized cutting subsystem 20 is a customized CNC laser cutting machine or a customized cutting module that includes a modified bed and a non-contact cutter adapted to garment panel dimensions. The customized cutting module 800 further includes an enlarged honeycomb bed configured to accommodate garment panels and a laser head having a modified motion range, wherein the configuration enables high-precision, non-contact cutting of fabric panels without causing edge burning. The customized cutting module is integrated with a digital orchestration layer such that order-specific SKU patterns are cut within 30 seconds per panel, thereby reducing manual intervention and minimizing fabric distortion.
[0079]
According to an embodiment herein, the present invention provides a computer-implemented method of just-in-time garment manufacturing, comprising a sequence of coordinated steps. The method begins with receiving an order and generating a job ticket that includes key information such as SKU, size, fabric type, and design details. Upon receiving the order, the base fabric is pre-processed within 24 hours to prepare it for subsequent coloration processes. The pre-processed fabric is then subjected to printing, dyeing, or embroidery operations, where an ICC-calibrated profile associated with the fabric type is applied to ensure color accuracy and consistency.
[0080]
Following coloration, the fabric is cut into garment panels on a customized bed using a non-contact cutter configured according to SKU-linked graded patterns. This ensures precision cutting while maintaining the integrity of the fabric edges. The job
23
ticket is then assigned to a tailoring workstation, where stitch instructions are transmitted and a timer is initiated once the job is accepted for processing. The tailored garment is subsequently assembled and subjected to a quality-checking process to ensure adherence to manufacturing standards.
[0081]
Once the garment passes quality checks, it is packaged, labeled with a machine-readable identifier, and dispatched to the customer. Additionally, a genealogy record is stored, capturing relevant machine parameters, operator IDs, timer data, ICC profile IDs, and dispatch information for traceability and process optimization.
[0082]
In one embodiment, tailoring instructions are generated from the same SKU-linked graded pattern used in the cutting process, thereby eliminating potential errors arising from human interpretation. The digital orchestration layer is further configured to generate sustainability reports for each order, including metrics related to water savings, energy reduction, and fabric waste elimination. The cutting step is enhanced by using a honeycomb support structure combined with a tuned non-contact laser process, preventing fraying or burning while maintaining edge integrity.
[0083]
The washing step is designed to handle fabric lots containing multiple unique printed designs in parallel, with lengths ranging from 1 to 3 meters. A controlled washing process is applied to prevent color transfer between adjacent designs. Additionally, transmitting stitch instructions is achieved by sending SKU-specific images and assembly guidelines to remote tailoring partners via a mobile interface, allowing remotely stitched garments to be returned for quality control before final dispatch.
[0084]
The method further includes generating augmented reality (AR) or virtual reality (VR)-based virtual samples using base garment silhouettes. These virtual samples overlay order-specific prints, colors, or textures to enable customer confirmation and direct routing of selections into the manufacturing pipeline. This ensures that the corresponding physical garments are manufactured and dispatched within 48 hours of order confirmation.
[0085]
In another embodiment, customer selections are received in a retail environment, where customers physically try a base garment sample and preview variations through AR/VR displays. Once a customer confirms an order, it is processed through the just-in-
24
time manufacturing pipeline and delivered within 48 hours to provide an efficient, interactive, and personalized shopping experience.
[0086]
Thus, the present system and method offer several advantages, including a significantly reduced production turnaround by integrating pre-processed base fabrics with digitally orchestrated manufacturing steps that govern printing, cutting, and assembly with precision. The system further minimizes waste and inventory overhead by manufacturing garments on a just-in-time basis, conforming to customer orders, while sustaining high quality through rigorous digital color management and traceability protocols. The integration of real-time monitoring and digital record keeping confers enhanced traceability, which serves both operational optimization and anti-counterfeit measures. These technical features collectively contribute to environmental and economic benefits by ensuring efficient resource utilization and rapid response to market demands.
[0087]
While embodiments of the present disclosure have been illustrated and described, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the scope of the disclosure, as described in the claims.
25
CLAIMS
I/We claim:
1. An integrated garment manufacturing system (100), comprising:
a fabric pre-processing unit (12) configured to subject a fabric to controlled washing, sizing, and coating procedures for conditioning the fabric and modifying surface energy;
a digital order orchestration controller (14) configured to capture customer orders from an online interface and convert each order into a digital job ticket comprising: design, color, size, and fabric requirements;
a color management module (16) comprising an International Color Consortium (ICC) profile library and a raster image processor (RIP) configured to select and apply a fabric-specific ICC profile to the fabric during a digital printing process, wherein the color management module (16) controls ink flow, color balance, and reproduction to adhere to a color difference threshold;
a digital textile printing subsystem (18) configured to receive pre-processed fabric and digital job ticket data to apply a desired design onto designated garment panel areas via a precision printing head;
a customized cutting subsystem (20) comprising a modified cutting bed and a non-contact laser cutting mechanism configured to receive SKU-linked graded patterns from the digital order orchestration controller (14) and execute cutting operations with precision path planning and controlled energy delivery;
a timer-linked tailor workstation (22) configured to receive a set of cut fabric panels and convert digitally generated graded patterns into stitching instructions, comprising a built-in timer that records assembly cycle times;
a quality control and dispatch subsystem (24) configured to inspect assembled garments using a set of automated inspection tools and a set of digital checklists and to affix a machine-readable identifier upon successful inspection;
a traceability and genealogy module (26) configured to record in a database a set of production parameters corresponding to each stage of manufacturing from fabric pre-
26
processing through one or more of: printing, cutting, tailoring, and quality control, wherein the customized cutting subsystem (20) is a customized CNC laser cutting machine that comprises a modified bed and a non-contact cutter adapted to garment panel dimensions,
2.The integrated garment manufacturing system (100) of claim 1, wherein thecustomized CNC laser cutting machine comprises an enlarged honeycomb bed adapted to garment panel dimensions and a laser head with modified motion range to enable a high-precision non-contact cutting of fabric panels without edge burning, wherein the system (100) is configured to complete the order-to-dispatch cycle within 48 hours of order placement.
3.The integrated garment manufacturing system (100) of claim 1, wherein thecustomized CNC laser cutting machine is integrated with a digital orchestration layer such that order-specific SKU patterns are cut within 30 seconds per panel to reduce manual intervention and eliminate fabric distortion.
4.The integrated garment manufacturing system (100) of claim 1, wherein the fabricpre-processing unit (12) further comprises an environmental control equipment configured to regulate temperature, humidity, and chemical dosages, and one or more quality check stations configured to log the processed fabric into the centralized genealogy record.
5.The integrated garment manufacturing system of claim 1, wherein the colormanagement module (16) is further configured to interact with the raster image processor (RIP) to dynamically adjust a set of printing parameters in accordance with the fabric type specified in the digital job ticket.
6.The integrated garment manufacturing system (100) of claim 1, wherein the digitaltextile printing subsystem (18) comprises a precision printing head and associated guidance mechanisms for controlled ink application on designated garment panel areas as dictated by the digital job ticket.
7.The integrated garment manufacturing system (100) of claim 1, wherein the timer-linked tailor workstation (22) comprises a mobile client device configured to display stitching instructions derived from the graded pattern and to initiate a local timer that records real-time assembly metrics.
8.The integrated garment manufacturing system (100) of claim 1, wherein thetraceability and genealogy module (26) is configured to continuously aggregate production
27
data, comprising a set of parameters received from the fabric pre-processing unit (12), the digital order orchestration controller (14), the color management module (16), the digital textile printing subsystem (18), the customized cutting subsystem (20), the timer-linked tailor workstation (22), and the quality control and dispatch subsystem (24) to generating a comprehensive digital record for each garment manufactured.
9.The integrated garment manufacturing system of claim 1, wherein the fabric pre-processing unit (12) is configured to perform a controlled washing protocol on a fabric lot comprising multiple parallel printed segments, each ranging from approximately 1 to 3 meters in length, wherein the washing protocol is optimized to prevent cross-color contamination between adjacent segments within a lot of up to approximately 200 meters in length.
10.The integrated garment manufacturing system of claim 1, wherein the digital textileprinting subsystem (18) is further configured to print a SKU-specific barcode directly onto the fabric panel during the printing process, wherein the barcode is configured to persist through subsequent fabric pre-processing steps including washing, and wherein the customized cutting subsystem (20) is configured to scan the barcode at the cutting stage to automatically retrieve and execute a corresponding cutting file, thereby eliminating mapping errors in micro-batches.
11.A computer-implemented method of just-in-time garment manufacturing comprisingthe steps of:
receiving an order and generating a job ticket comprising SKU, size, fabric type, and design;
pre-processing base fabric within 24 hours to prepare it for coloration;
applying printing, dyeing, or embroidery on the pre-processed fabric using an ICC-calibrated profile associated with the fabric type;
cutting garment panels on a customized bed with a non-contact cutter according to SKU-linked graded patterns;
assigning the job ticket to a tailoring workstation, transmitting stitch instructions, and initiating a timer upon job acceptance;
28
assembling and quality-checking the garment;
packaging, labeling with a machine-readable identifier, and dispatching the garment; and
storing a genealogy record comprising machine parameters, operator IDs, timer data, ICC profile IDs, and dispatch information,
12.The computer-implemented method of claim 11, wherein tailoring instructions aregenerated from the same SKU-linked graded pattern used in the cutting module, thereby eliminating human interpretation errors.
13.The computer-implemented method of claim 11, wherein transmitting stitchinstructions comprises sending SKU-specific images and assembly guidelines to remote tailoring partners via a mobile interface, the remotely stitched garment being returned to the facility for quality control before dispatch.
14.The computer-implemented method of claim 11, further comprising generatingAR/VR-based virtual samples from base garment silhouettes, overlaying order-specific prints, colors, or textures, and routing confirmed selections directly into the manufacturing pipeline, such that the corresponding physical garments are manufactured and dispatched within 48 hours.
Dated this on 17th September, 2025 Patent agent for the applicant
(JYOTI CHAUHAN)
Of GOLDEN IP LEGAL SERVICES
(IN/PA/1684)
29
ABSTRACT
Disclosed is an integrated garment manufacturing system in the textile field. The system includes a fabric pre-processing unit (12) for conditioning white or greige fabrics, a digital order orchestration controller (14) that converts online orders into digital job tickets, and a color management module (16) utilizing ICC profiles and a raster image processor for controlled ink application. A digital textile printing subsystem (18) applies designs to fabric panels, while a customized cutting subsystem (20) employs non-contact laser cutting with SKU-linked patterns. A timer-linked tailor workstation (22) executes stitching instructions with cycle time recording, and a quality control and dispatch subsystem (24) inspects and verifies the garments. A traceability module (26) records production parameters, ensuring a streamlined, responsive system for just-in-time garment manufacturing and 48-hour order fulfilment.
[FIG. 3] , C , C , Claims:I/We claim:
1. An integrated garment manufacturing system (100), comprising:
a fabric pre-processing unit (12) configured to subject a fabric to controlled washing, sizing, and coating procedures for conditioning the fabric and modifying surface energy;
a digital order orchestration controller (14) configured to capture customer orders from an online interface and convert each order into a digital job ticket comprising: design, color, size, and fabric requirements;
a color management module (16) comprising an International Color Consortium (ICC) profile library and a raster image processor (RIP) configured to select and apply a fabric-specific ICC profile to the fabric during a digital printing process, wherein the color management module (16) controls ink flow, color balance, and reproduction to adhere to a color difference threshold;
a digital textile printing subsystem (18) configured to receive pre-processed fabric and digital job ticket data to apply a desired design onto designated garment panel areas via a precision printing head;
a customized cutting subsystem (20) comprising a modified cutting bed and a non-contact laser cutting mechanism configured to receive SKU-linked graded patterns from the digital order orchestration controller (14) and execute cutting operations with precision path planning and controlled energy delivery;
a timer-linked tailor workstation (22) configured to receive a set of cut fabric panels and convert digitally generated graded patterns into stitching instructions, comprising a built-in timer that records assembly cycle times;
a quality control and dispatch subsystem (24) configured to inspect assembled garments using a set of automated inspection tools and a set of digital checklists and to affix a machine-readable identifier upon successful inspection;
a traceability and genealogy module (26) configured to record in a database a set of production parameters corresponding to each stage of manufacturing from fabric pre-processing through one or more of: printing, cutting, tailoring, and quality control, wherein the customized cutting subsystem (20) is a customized CNC laser cutting machine that comprises a modified bed and a non-contact cutter adapted to garment panel dimensions,
2.The integrated garment manufacturing system (100) of claim 1, wherein thecustomized CNC laser cutting machine comprises an enlarged honeycomb bed adapted to garment panel dimensions and a laser head with modified motion range to enable a high-precision non-contact cutting of fabric panels without edge burning, wherein the system (100) is configured to complete the order-to-dispatch cycle within 48 hours of order placement.
3.The integrated garment manufacturing system (100) of claim 1, wherein thecustomized CNC laser cutting machine is integrated with a digital orchestration layer such that order-specific SKU patterns are cut within 30 seconds per panel to reduce manual intervention and eliminate fabric distortion.
4.The integrated garment manufacturing system (100) of claim 1, wherein the fabricpre-processing unit (12) further comprises an environmental control equipment configured to regulate temperature, humidity, and chemical dosages, and one or more quality check stations configured to log the processed fabric into the centralized genealogy record.
5.The integrated garment manufacturing system of claim 1, wherein the colormanagement module (16) is further configured to interact with the raster image processor (RIP) to dynamically adjust a set of printing parameters in accordance with the fabric type specified in the digital job ticket.
6.The integrated garment manufacturing system (100) of claim 1, wherein the digitaltextile printing subsystem (18) comprises a precision printing head and associated guidance mechanisms for controlled ink application on designated garment panel areas as dictated by the digital job ticket.
7.The integrated garment manufacturing system (100) of claim 1, wherein the timer-linked tailor workstation (22) comprises a mobile client device configured to display stitching instructions derived from the graded pattern and to initiate a local timer that records real-time assembly metrics.
8.The integrated garment manufacturing system (100) of claim 1, wherein thetraceability and genealogy module (26) is configured to continuously aggregate production.
data, comprising a set of parameters received from the fabric pre-processing unit (12), the digital order orchestration controller (14), the color management module (16), the digital textile printing subsystem (18), the customized cutting subsystem (20), the timer-linked tailor workstation (22), and the quality control and dispatch subsystem (24) to generating a comprehensive digital record for each garment manufactured.
9.The integrated garment manufacturing system of claim 1, wherein the fabric pre-processing unit (12) is configured to perform a controlled washing protocol on a fabric lot comprising multiple parallel printed segments, each ranging from approximately 1 to 3 meters in length, wherein the washing protocol is optimized to prevent cross-color contamination between adjacent segments within a lot of up to approximately 200 meters in length.
10.The integrated garment manufacturing system of claim 1, wherein the digital textileprinting subsystem (18) is further configured to print a SKU-specific barcode directly onto the fabric panel during the printing process, wherein the barcode is configured to persist through subsequent fabric pre-processing steps including washing, and wherein the customized cutting subsystem (20) is configured to scan the barcode at the cutting stage to automatically retrieve and execute a corresponding cutting file, thereby eliminating mapping errors in micro-batches.
11.A computer-implemented method of just-in-time garment manufacturing comprisingthe steps of:
receiving an order and generating a job ticket comprising SKU, size, fabric type, and design;
pre-processing base fabric within 24 hours to prepare it for coloration;
applying printing, dyeing, or embroidery on the pre-processed fabric using an ICC-calibrated profile associated with the fabric type;
cutting garment panels on a customized bed with a non-contact cutter according to SKU-linked graded patterns;
assigning the job ticket to a tailoring workstation, transmitting stitch instructions, and initiating a timer upon job acceptance;
assembling and quality-checking the garment;
packaging, labeling with a machine-readable identifier, and dispatching the garment; and
storing a genealogy record comprising machine parameters, operator IDs, timer data, ICC profile IDs, and dispatch information,
12.The computer-implemented method of claim 11, wherein tailoring instructions aregenerated from the same SKU-linked graded pattern used in the cutting module, thereby eliminating human interpretation errors.
13.The computer-implemented method of claim 11, wherein transmitting stitchinstructions comprises sending SKU-specific images and assembly guidelines to remote tailoring partners via a mobile interface, the remotely stitched garment being returned to the facility for quality control before dispatch.
14.The computer-implemented method of claim 11, further comprising generatingAR/VR-based virtual samples from base garment silhouettes, overlaying order-specific prints, colors, or textures, and routing confirmed selections directly into the manufacturing pipeline, such that the corresponding physical garments are manufactured and dispatched within 48 hours.
Dated this on 17th September, 2025 Patent agent for the applicant
(JYOTI CHAUHAN)
Of GOLDEN IP LEGAL SERVICES
(IN/PA/1684)