Study of contact pressure and breast displacement in sports bras using finite element method

Purpose This paper aims to analyze the contact pressure and displacement in varying support strength bras at different movement speeds using finite element (FE) simulation, providing a theoretical and data-driven basis for designing comfortable and functional sports bras. Design/methodology/approach Utilizing a 3D scanning system, reverse engineering software, and SolidWorks, a “torso-breast” model and a bra geometric model were constructed. ABAQUS was then used to develop a “torso-breast-bra” FE contact mechanics model. Material properties and constraints were adjusted to simulate dynamic and static pressure distributions and breast displacements under varying support strengths and movement velocities. Findings The root mean square errors (RMSE) between the simulated and actual results for contact pressure and displacement were 8.13% and 10.11%, respectively, with a high correlation coefficient (R) of 0.97, indicating accurate simulations. As the intensity of the exercise escalates, fluctuations in pressure within the breast area become more accentuated, particularly in the lower breast region. Concurrently, the range of relative displacement of the breasts in the X, Y and Z directions also escalates. Specifically, when the speed increases from 6 km/h to 8 km/h, the displacement increment in the Z direction is approximately twice that in the X direction. In addition, wearing a high-support sports bra effectively reduce breast motion and improve exercise comfort. Originality/value This research provides an effective method for predicting dynamic and static contact pressures and breast displacement, essential for improving bra design, enhancing comfort and protecting health.