Your Next Pair of Walmart Pants Could Be 3D Woven

An anonymous reader quotes a report from Wired: We've been ableto design and 3D-print plastic phone cases and toys at home for a decade now. For almost every other consumer product made in a factory, the robots have taken over the heavy lifting. But fashion is still stuck in the 20th century. Take a typical pair of chinos. Cotton threads are woven on a large loom at a mill somewhere in Asia, then shipped to a dye house, then shipped (usually a great distance) to a garment factory somewhere else in Asia. There, the fabric is laid flat and cut into shapes, with the excess fabric being landfilled, incinerated, or (very rarely) recycled. Underpaid and exploited garment workers hand-sew those pieces of fabric into pants, which are then shipped across the ocean to a fulfillment warehouse or a store near you. This global apparel supply chain is inefficient and emissions-heavy -- an estimated 4 percent of global waste and 2 to 4 percent of greenhouse gas emissions are attributed to fashion production. Brands have to make risky predictions many months in advance about which items will sell, leading them to over order on a massive scale.

Now, Walmart is piloting a project with the San Francisco Bay area startup Unspun to test whether it can manufacture the retailer's in-house brand of chinos in the US using a technology called 3D weaving. The experiment is part of a push to nearshore Walmart's supply chain and cut down on emissions and waste associated with textile production. While still very much in the prototype phase -- the two companies are exploring how to use Unspun's technology to supply pants to Walmart's stores -- if successful, this project could upend the way apparel is manufactured on a huge scale. Unspun hopes to eventually deploy 3D weaving micro-factories throughout the United States, so that anyone can order custom and locally made apparel on demand.

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