Individualna prilagoditev oblike oporne žice v nedrčku

Conventional brassiere underwires often cause discomfort due to localized pressure concentrations, leading to wearer discomfort and potential long-term health concerns. This study investigates the application of 3D printing technology for designing and fabricating customized brassiere underwires aimed at improving pressure distribution and structural comfort. A 3D body scan of the under-bust profile was utilized to develop a personalized underwire model, which was fabricated using fused deposition modelling (FDM) with acrylonitrile butadiene styrene (ABS) material. To evaluate performance, pressure exertion tests were conducted using force-sensitive sensors positioned at three anatomical points, Point A (base region), Point B (medial region, near the sternum) and Point C (lateral region, near the underarm), under both static and dynamic conditions. The 3D-printed underwire demonstrated significant reductions in localized pressure compared to the conventional stainless-steel underwire, achieving decreases of 36.36% at Point A, 38.10% at Point B and 35.00% at Point C under static conditions, and 24.00%, 21.74% and 22.22%, respectively, under dynamic conditions. Complementary finite element analysis (FEA) was performed to simulate structural deflection under breast loads ranging from 0.5 kg to 0.8 kg. The results indicated that the maximum deflection increased from 1.48 mm to 2.37 mm, while average deflection rose from 0.80 mm to 1.28 mm, demonstrating a linear elastic behaviour consistent with the mechanical properties of ABS (Young’s modulus ≈ 2.0 GPa) compared to stainless steel (≈ 200 GPa). The deformation contour confirmed effective load distribution with minimal deflection in the constrained regions, validating structural stability. Overall, the findings establish that 3D-printed ABS underwires provide improved comfort, controlled flexibility and reliable mechanical performance, making them a viable alternative to traditional metallic underwires. This research highlights the potential of additive manufacturing in the intimate apparel industry, enabling mass customization, enhanced anatomical conformity and improved wearer satisfaction beyond conventional mass-produced designs.