Mechanical and pressure optimization of torso compression garments

This study presents a comprehensive evaluation of warp-knit, rib, and interlock spacer fabrics for multi-level torso compression garments, highlighting novel insights into their mechanical performance and design optimization. Interlock spacer fabrics exhibited superior stretchability, with elongation at break of 422–518% (wale) and 298–352% (course), and maximum loads of 394–435 N (wale) and 516–901 N (course), surpassing warp-knit and rib fabrics in tensile strength. Elastane content strongly influenced recovery and stress relaxation; fabrics containing 31% elastane nearly fully recovered (99.96–100%), with minimal stress relaxation (3.97% wale, 3.91% course), revealing a robust correlation with elastane proportion (R2 = 0.836–0.970). Predictive modeling enabled precise pattern adjustments to achieve target compression levels. Prototype garments exhibited generally uniform pressure distribution, although lower pressure was observed at the central torso due to body concavity and limited surface contact. These findings provide novel quantitative evidence and practical guidance for optimizing mechanical performance and pressure control in clinical and athletic compression garments.