Applying Generative Design to the Development of Advanced Protective Wearables via Additive Manufacturing Technology

Generative design is a multi-objective design exploration tool that has revolutionized the way products are designed and it is being integrated in common Computer-Aided Design (CAD) software to enable quick prototyping and manufacture of parts with optimized performance, namely stiffness maximization and lightweighting. It is driven by powerful artificial intelligence (AI) models, such as the Generative Adversarial Networks (GANs) and Evolutionary algorithms which operates via the generator-discriminator and iteration-recombination optimization processes respectively. In this study, generative design was considered to create advanced 3D printed fabric structures to serve as protective wearables in various applications. Other than being functional, key attributes of the proposed prototype, which was designed on the CAD software of Fusion 360, was conceptualized to have a reduced overall weight without compromising on its mechanical performance. Three design iterations of the functional 3D-printed fabrics based on the chain mail fabric first introduced by NASA, were successfully developed in this study by considering AI technology. The benefits of generative design in the optimization of advanced wearable fabrics will be assessed by comparing and benchmarking the proposed design with conventionally designed ones. The results are expected to further demonstrate the notable benefits of generative design to produce an optimized wearable fabric for improved comfortability. This study is a first step in the development of highly advanced and functional wearable fabrics by considering AI technology for strength-to-weight optimization and Finite Element Method (FEM) for further structural validation. The findings of this study will also be beneficial for research and development in the field of wear resistant wearables, advanced textile materials and protective gears.