Innovations in the bra cup molding processes

There is an consistent large demand for seamless molded bras, representing almost 80–90% of the overall bra market. Not only does a smoothly molded cup surface have a natural configuration under an outer garment, but the significance also lies in the fact that molded bras provide unlimited designs with different levels of softness and support. However, the design of mold heads and the manufacturing processes of bra molding are highly complex. They involve many kinds of cushioning and support materials to be molded together with innovative technologies. Essentially, a scientific method is needed to characterize and evaluate the three-dimensional geometry of molded cups. The optimization of the molding process parameters in relation to the large range of cup sizes and new advances in molding materials is also a longstanding problem in controlling the efficiency of the process and product quality. This chapter provides detailed information about advances in the bra cup molding process in intimate apparel manufacturing.