Group Engineering Proposal Essay

Mahir Shahriar & Mohammed Yacoub

City College of New York

Professor Sara Jacobson

ENGL 21007 Writing For Engineering

Group Engineering Proposal Essay

Introduction

Sewing machines are one of the most impactful inventions ever created. Before the creation of sewing machines, all the clothes people wore were sewn by hand, mostly by housewives. The process of hand-sewing clothes was not only arduous to the person making the clothes but also extremely time-consuming. Making a single piece of clothing could take the entire day or even longer. The invention of the sewing machine enabled people to expedite the process but also allowed them to commercialize the process by having factories where people could make clothes nonstop. Over time, many improvements have been made to sewing machines to be both time and energy-efficient and yield better results through stronger stitching techniques. However, one part of innovation that hasn’t seen much thought is fully autonomous sewing machines. When we mean fully autonomous sewing machines, we don’t mean sewing machines where the needle bobs up and down by itself and the stitching just happens as you move the clothing on the machine, that’s just a normal sewing machine. What we mean by a fully autonomous sewing machine is a sewing machine that can perform exactly what is needed of it without much human input. For a normal sewing machine, you need to properly position the clothing in the right area, have the skill to properly move that clothing as the machine is running at the correct pace, and know exactly how to tackle the problem you are trying to fix, whether it’d patching a small hole in a piece of clothing or an extremely large tear. For our autonomous sewing machine, the user would have a screen to select what they wanted the sewing machine to do. For example, let’s say there was a hole in a shirt that you wanted to patch. You would place the shirt into the machine and select that you wanted to patch a hole. The sewing machine would then scan the shirt to find out exactly where the hole was and it would patch it using the appropriate colors. This eliminates the need to have experience sewing as the machine would do everything for you with minimal error. This is especially needed nowadays where sewing is a bygone hobby. Most people belonging to the Gen Z group have never even seen a sewing machine and for small tears in clothing, just throw the entire thing out; giving them zero experience and knowledge about sewing.

This kind of innovation is only made possible with advancements in scanner technology. A big part of our sewing machine is that it can repair these items of clothing without the user needing to do any work. The scanner finds the tear, positions the machine in the correct position, and uses the correct coloring to have the most concealed stitching possible unless the user desires otherwise. So much can go wrong with the stitching if the clothing isn’t positioned correctly and accurately, so using scanner technology and computer input will get the best possible result. 

When thinking of where we could innovate something for this project, we initially looked at the education system. After all, we are all college students. Initially, we looked at holograms that could be used for education, allowing a more hands-on and realistic experience of things that normally teachers would show on screens or only be able to explain theoretically. However, this concept is extremely difficult to execute. One of our main inspirations was Disney, but even their model wasn’t fully fitted out. We then turned to something we all had in common; we all wore clothes. A very normal thing, yes, but we realized that once one of our clothes was damaged, we just threw it out and bought completely brand new clothing, wasting a lot of money for even the smallest of tears. We knew that people could sew to fix those, except we didn’t know anyone who knew how to. There, we found our problem; people weren’t sewing. How could we solve this problem? Many people don’t get into sewing as it takes a considerable amount of time to learn, and without proper training, people could not only further damage the clothing they are trying to fix; they could also be hurting themselves when they make a mistake. We also thought about the time efficiency of sewing. While sewing machines have developed enough to where sewing doesn’t take that long, maybe a 30-minute endeavor, many people would much rather spend that time doing something else rather than attempting to fix some clothing that they could ultimately mess up. To that end, we thought, why not make the machine do all the work for the user? If the machine is doing all the work, that gets rid of the learning curve that comes with purchasing a sewing machine, a factor keeping many people from buying one. It also gets rid of the time problem. While the automatic machine is still going to take the same amount of time as sewing with a normal sewing machine, it allows the user to step away and use that time to do something else, rather than sit at the machine to sew. It also increases the success rate of good stitching. There is no human error that can mess up the stitching, which means people will always be happy with the results. 

To build this, we needed to come up with how we were going to change the position of the stitching, either by figuring out a way how we could move the clothing or moving the needle and bobbin thread that sits in the shuttle underneath the clothing. To this end, we decided that it would be easier to allow the needle and shuttle to move while keeping the actual clothing still. To accomplish this, we took inspiration from a 3D printer, as those can change the height of the feeder of the 3D printer, or in our case the needle of the sewing machine, horizontally, vertically, and longitudinally. This is further explained in the technical description. The cost to make this is very similar to that of a 3D printer. The actual price to make a 3D printer is around $700, and our product should be very similar in price. It would use the same metals as a 3D printer, those being aluminum, stainless steel, and titanium. The magnets used in the machine to hold down the clothing would be a couple of dollars for customers to buy, but for the manufacturers, that being us, would only cost around $1 or less. The cost of making the needle and its housing, along with the shuttle would be offset from the total cost of manufacturing as it is largely the same cost to make the feeder for a 3D printer, the part that is being replaced by the needle, its housing, and the shuttle. However, that $1300 manufacturing cost isn’t very honest, as it does not take into account how manufacturers can get the materials much cheaper than average consumers as they buy them in bulk. For the average person to be able to put together something like this, given all the parts, it would take them a week or more. But, as the manufacturer, we have factories that can mass-create the parts and put them together, bringing the time to create this machine from over a week, to being able to make a large quantity of them in a given workday.

Market Competition and Failed Innovation

SewBo 

              A company that approached automation within the sewing industry through a robotic arm capable of moving any fabric that has been imbued with a water-soluble stiffener through suctions was because of “The difficulties robots face when trying to manipulate limp flexible fabrics” Therefore, applying the water-soluble stiffener would solidify the fabrics allowing for easy manipulation of the fabric. This also can be easily removed with the application of hot water. Their stiffener can easily be recovered after use.

The Sewbot

             Using CNC Technology software automation, an Atlanta-based company, has developed the Sewbot, which is a fully automated garment-producing machine. Recently, they partnered with Tianyuan Garments, a Chinese company, to establish a fully automated T-shirt production line in Little Rock, Arkansas. The Sewbot can produce one T-shirt every 22 seconds, resulting in 800,00-0 T-shirts per day for Adidas. With complete automation, the personnel cost for each T-shirt is approximately 33 cents, making it difficult for even the cheapest labor markets to complete. While this development signifies American Technology competing with and potentially replacing Chinese jobs, The factory in Little Rock will only create around 400 jobs, significantly fewer than the traditional garment manufacturing methods would require for such a high production volume. 

Our Spotlight

        An automated sewing machine is typically geared towards streamlining and optimizing the manufacturing process by handling repetitive tasks with high speed and precision. These machines are typically equipped with machine vision and robotics to cut, sew, and assemble garments with minimal human intervention. They are programmed to operate continuously and efficiently, enabling mass production of garments with minimal human intervention. They are programmed to operate continuously and efficiently, enabling mass production of garments at a rapid pace.

On the other hand, our goal is directly focused on the repair and maintenance of already-produced clothing. Our product comes with additional features such as thread tension adjustment, stitch selection, and pattern recognition aimed to assist users in fixing any type of damage in clothing or other fabrics, to be user-friendly, versatile, and easily usable. If the individual desires to address a specific issue without extensive sewing expertise they would be able to come to our product and operate it effectively

The Intended Market

         Industry manufacturers, garment production, and your everyday person who might not want to throw away a damaged clothing piece. With thorough market research, this product might be applicable in all the previously mentioned criteria. What is more worrying is how to effectively enter said market, there should be multiple aspects of consideration; such as consumer demand, through which we will need to conduct quantitative data analysis of our impact on the market, sales figures, and website traffic. Using kiosk technology provides us opportunities in direct-retail markets, where companies like Macy’s, Zara, Marshals, and Nordstrom could offer our technology in their stores increasing their targeted consumers into diverse demographics. This would enable us to be more differentiated from our market competitors, while still engaging in the same playing field. While the machine itself will not be very profitable, as our production cost will be $700, and our market price for consumers to purchase will be at a $900 price tag, most of our company’s profits will solely be from the sale of our specialized threads which are only compatible with our sewing machine. These threads can easily be made at $0.50 a piece and sold at a 400% mark-up price of $4.50.

TECHNICAL DESCRIPTION

EXTERIOR SHELL

          Designing the external shell of our automatic sewing machine to resemble the shell of a claw machine offers numerous benefits, particularly in enhancing child safety and overall usability. Taking cues from the sturdy construction and secure access points of claw machines, the sewing machine’s shell can be fortified with reinforced panels and durable materials to deter unauthorized access, especially by children. By incorporating locking mechanisms or secure closures, the shell ensures that only authorized users can access the machine’s internal components, minimizing the risk of accidents or damage. Additionally, integrating transparent plastic elements into the shell design allows users to monitor the machine’s operation, providing a sense of security and affirmation for the protection of their fabric. Furthermore, adopting interactive controls and child-friendly aesthetics reminiscent of claw machines enhances user engagement while reducing the likelihood of injuries from sharp edges or corners.

Selling only the shell of the automatic sewing machine with the attached kiosk machine to retail markets introduces a novel concept that combines functionality with convenience. This approach allows companies like Macy’s to retrofit their existing sewing machines with a kiosk interface, enhancing their capabilities and user experience without the need for a full machine replacement. The shell, equipped with the kiosk machine, serves as a versatile add-on accessory dedicated to appeal to retail markets that can be easily installed onto compatible sewing machines. By offering the shell separately, manufacturers will only be able to access this aspect of our product, which will help differentiate it from those sold to regular consumers. Furthermore, selling the shell with the attached kiosk separately enables retailers to cater to different customer preferences and budget constraints, expanding market reach and appeal. 

Designing the USER INTERFACE

Kiosk machines often feature user-friendly interfaces designed for quick and easy interaction, the display can offer effortless navigation through stitching options and settings. This also will be enhanced by adding touchscreen technology to appeal to user engagement and simplify selection processes, Real-time visual feedback, akin to kiosk displays, aids users with stitch previews and troubleshooting guidance. Customizable settings cater to individual preferences, while multifunctionality extends the display’s utility beyond stitch selection, providing instructional videos and maintenance tips.

With a sleek and modern design inspired by modern kiosks, the display seamlessly integrates into various environments, enriching the machine’s aesthetic appeal. By leveraging these design principles we can elevate user experiences, making tasks more accessible and enjoyable. This also allows for control of various aspects of the stitch settings, specifically the type of stitch desired and what type of sewing technique is desired such as a patch or a regular stitch. The screen that will be used in our model will be a 24-inch screen and most importantly touch enhanced for users to select the option that caters to their needs.

Processor and Motherboard

The central processing unit and motherboard are from the core of the kiosk’s computing system. They handle data processing, manage software applications, and control the overall operation of the kiosk. For example, Mcdonald’s kiosk self-service machines only needed the Intel Core I5-470TE CPU at 2,70 GHz, with only 3.7 gigabytes of memory storage 

Also as the requirement for memory storage isn’t as excessive we can do just fine with a 10 GB SSD, which will enable high-speed software updates, and add any changes required for the software aspect of scanning the positioning of the fabric.

The Frame:

Sewing machine design, featuring a plastic bed, integrated power switch, and wire connectors seamlessly incorporated into the machine’s frame. The plastic bed, leveraging the lightweight, nonmagnetic material and customizable nature of plastic, offers enhanced maneuverability and fabric control while maintaining stability during sewing. Integrated within easy reach on the bottom corner of the frame, the power switch optimizes user convenience and safety, Furthermore, wire connectors, embedded directly into the frame, ensure reliable electrical connections, simplifying assembly and enhancing overall reliability. Importantly, housing the controller within the main body protects against external elements, such as dust and debris, while also aiding in efficient heat dissipation generated during the printing process. Additionally, this location enables better management of wiring and cables, contributing to smoother operation and easier maintenance of the sewing machine over time.

The inclusion of a screw on the side of the sewing machine, which, when opened, allows for the insertion of desired threads, offers both convenience and practicality to users. This feature showcases the process of thread selection and casually indicates how third-party threads won’t be compatible with our product. While openly enabling users to quickly and easily switch between different thread types or colors without the need for complex adjustments or disassembly. Moreover, the accessibility provided by this screw facilitates effortless maintenance and repair of the sewing machine- Users can easily access the internal mechanisms and components, such as the bobbin case or tension discs, for cleaning, lubrication, or troubleshooting purposes. By incorporating this user-friendly design element, the sewing machine enhances both usability and serviceability.

The sewing mechanism is inspired by cartesian 3D printers, which can move along 3 linear axes- X, Y, and Z). Allowing the sewing needle to precisely hit the targeted area. In Cartesian 3D printers, the movement along the X, Y, and Z axes is typically controlled by stepper motors. Stepper motors are widely used in 3D printers due to their precise control, reliability, and affordability. These motors could be directly applied to our automatic sewer similarly.

The X-axis motor is responsible for moving the needle head horizontally along the X-axis. Mounted on the printer’s frame and connected to a belt the movement of the sewing head. The motor receives commands from the machine’s controller, instructing it to move the head to specific positions with precise accuracy.

 Similar to the X-axis motor, the Y-axis motor moves the needle horizontally along the Y-axis. It is also mounted on the frame and connected to a belt that drives the movement of the print bed. Like the X-axis motor, the Y-axis motor receives commands from the controller to move the machine to the desired positions.

The Z-axis motor controls the vertical movement of the needle head. It is located at the top of the of the sewing machine and connected to a screw mechanism that raises or lowers the print head. The Z-axis motor receives commands from the controller to adjust the height of the head, allowing for the layer-by-layer incineration of fabric threads during the repair process.

(Florian, D. Building a 3D Printer: Stepper Motors. Dr. D-Flo.)

The motors Operate by converting electrical pulses from the controller into incremental movements of the motor shaft, allowing for accurate positioning of the needle or bed. Additionally, stepper motors have torque, meaning they can hold their position without the needle for continuous power, which is essential for maintaining positional accuracy during the repairing process.

There will also be two additional X and Y motors on the bottom to move an electromagnet on the bottom whose purpose is to move a steel-plated bottom which is made to hold the second thread mechanism and move around freely in 2 dimensions. There also are 4 magnetic pieces designed as clips not to be confused with the Steel-plated holder meant to hold the fabric in place. 

The Laser Technology

  In our sewing machines, laser distance sensors are invaluable for enhancing precision and efficiency in the sewing process. These sensors utilize laser technology to accurately measure distances between the fabric, the bed of the sewing machine, and the needle. By emitting a laser beam towards the target fabrics and analyzing the time it takes for the beam to reflect back to the sensor, these devices can determine distances with high accuracy. This capability enables a range of applications; including measuring fabric thickness, detecting fabric alignment on the bed, and ensuring proper needle positioning. 

Combining laser distance sensors with our already-established kiosk machines can revolutionize the sewing experience. As users approach the kiosk and place their fabric, the laser sensors spring into action, detecting the fabric’s presence and measuring its thickness. Simultaneously, the kiosk’s display screen illuminates with step-by-step images or animations guiding users on how to position the fabric correctly on the sewing machine’s bed. This real-time guidance ensures that users align their fabric precisely before sewing repair begins. Moreover, the laser sensors provide immediate feedback on fabric alignment and thickness, allowing the kiosk to automatically adjust the sewing machine settings for optimal performance. If any deviations are detected, the kiosk can alert users and suggest corrective actions, ensuring error-free fabric placement. By seamlessly integrating visual instructions with laser precision, this system streamlines the sewing process, reduces errors, and empowers users of all skill levels to achieve professional-quality results with ease. 

The Magnetic Clips 

Magnetic clips are a game-changer, offering a secure and efficient method for holding clothing pieces in place during the sewing process. Their strong magnetic force ensures a firm hold on fabric layers without causing any damage or leaving behind unsightly marks. Whether it’s garments, hems, cuffs, or seams, magnetic clips provide versatility, making them suitable for a wide range of sewing tasks. What makes them particularly appealing is their accessibility- easy to apply and remove with just a touch, making them perfect for users with limited dexterity or mobility. Unlike traditional sewing pins or clips, magnetic clips lie flat against the fabric, minimizing interference with the sewing machine’s needle and allowing for an uninterrupted stitching process.  This will go hand in hand with the previously mentioned Laser system, as it will indicate on the bed of the sewing machine where to precisely place each magnetic clip. 

Conclusion

So much money is being wasted every year by people throwing away perfectly good clothing just because of tears and holes that they are unable to fix. Those who attempt to repair these clothing are often put off by the process of sewing, noting how sewing is a skill that takes a long time to properly learn, and without that skill, they risk damaging the clothing they are trying to repair, and injuring themselves through improper use of a sewing machine. Our sewing machine offers a great solution to this. With it being automatic, the machine does all the work, eliminating the risk factor of injuring the user or damaging the clothing, getting rid of that learning curve that drives so many away from sewing, and allowing people to better allocate their time doing other tasks while the machine is fixing their clothing. Although challenges such as competition from other manufacturers and initial costs are high, our design can offer an innovative solution to the clothing waste problem, and over time, can generate large profits from clothing material sales and other products centered around the automatic sewing machine. The future of sewing is here, and this power of automation coming together with sewing machines can become as impactful to the world as the first sewing machine was.   

References

Admin, S. (2024, May 5). How did the Sewing Machine Impact the Industrial Revolution?. Industrial Embroidery Machines & Sewing Equipment Suppliers. https://www.stocks.co.uk/blog/how-did-sewing-machine-impact-industrial-revolution.html#:~:text=The%20sewing%20machine%20shifted%20the,factories%2C%20increasing%20their%20family’s%20income. 

Florian, D. (n.d.). Building a 3D Printer: Stepper Motors. Dr. D-Flo. https://www.drdflo.com/pages/Guides/How-to-Build-a-3D-Printer/Stepper-Motor.html

Specs of a McDonald’s kiosk in more detail. You’re welcome. : r/PBSOD. (2023, January 24) Reddit. 

Specs of a McDonald’s kiosk in more detail. You’re welcome.
byu/tamay-idk inPBSOD