3D finite-element-based orthogonal design for optimization of adjustable bras with pressure fit and shaping effect

Adjustable bras are well designed to offer optimal support and shaping for the breasts, by employing scientifically determined pressure distribution. The bras are favored for their ability to balance the multidimensional needs of comfort, functionality, and safety. Based on a finite-element model of the body–bra system and orthogonal design, the effect of various factors on the performance of bras was investigated, including Young’s modulus of the shoulder straps and cups, as well as the thickness of soft tissue. The simulation results indicated that as the Young’s modulus of straps and cups increases, the contact pressure at each test point also increases, while the shaping effect decreases. Regression equations were established to quantify the relationships between contact pressure, shaping indicator, and Young’s modulus of the shoulder straps and cups. Furthermore, as the thickness of the soft tissue increases, there is a decreasing trend in contact pressure and stress, and an increasing trend in deformation. This highlights the importance of considering individual anatomical variations when designing bras to ensure a proper fit and optimal support. The study explored a deeper understanding of interaction mechanisms between body and bras, which scientifically guide the optimization of bra design, including style, pattern, and fabric selection, to better meet the needs of diverse body types. In addition, the methodology and findings can inspire and inform the simulation and design of other types of garments, potentially leading to improvements in the fit and functionality of a wide range of clothing items.