Skip to Main Content
3D Knitting On-Demand: The Supply Chain of the Future

3D Knitting On-Demand: The Supply Chain of the Future

Good morning gentlemen (and ladies),

I want to share an innovation in garment manufacturing that I’m really excited about; 3D Knitting.

In my opinion, it represents the supply chain of the future; where on-demand production becomes so efficient that it replaces bulk production (which produces millions of pounds of waste every year and is one of the leading causes of greenhouse gas emissions).

We talk a lot about shopping sustainably here at AOS, primarily through the lens of:

1) Made-to-Order products to eliminate inventory and over production
2) Bespoke fittings to ensure garments are loved and will not get replaced
3) Quality craftsmanship x timeliness design - to last the test of time and never go “out of style”
4) Using only all natural fabrics (not synthetics which create microplastics in washing)
5) Manufacturing in America and providing transparency into our factories

But sustainable knitwear has always provided a challenge.

The problem with knitwear is that it typically requires large minimum orders from manufacturers who produce in bulk-only. So brands and designers have to try their best to predict exactly how many units (per color and per size) they will be able to sell in the upcoming season(s). But accurate predictions are impossible, especially given how quickly the apparel industry is changing. Inevitably, there are millions of garments made that nobody wants. So brands mark these garments down again and again, until they're 90% off and somebody buys it “just because” (and eventually discards it). This cycle creates an unthinkable amount of waste and destruction throughout the entire supply chain

But not anymore.

New state-of-the-art 3D knitting technology (which we have dubbed “Zero Waste Knitwear”) solves this problem by using on-demand whole-garment technology to eliminate waste - all while revitalizing a historic garment trade in Brooklyn New York.

“3D knitting” or “whole garment technology” produces an entire garment using one single piece of yarn. This makes a “seamless” knit that is unmatched in terms of comfort, and even more unmatched in terms of sustainability and scalability.

The efficiency of this technology allows us to make a whole garment in a matter of minutes, rather than weeks. Therefore, it provides the speed and convenience of a “ready to wear” shopping experience, with the peace of mind of knowing that you're supporting a supply chain that is ethical and environmentally friendly.

And it’s all made in Brooklyn New York - the former Mecca of knitwear in the USA.

A 3D Knitting machine in Brooklyn NY, making our Gentleman's Tee LS in black

Brooklyn was once the hub of garment manufacturing, with almost one third of American workers in the garment trade. Not too long after the 1960's, overseas production became the new norm, where human labor and materials became cheap and cost-effective. Fast-forward to the 21st Century, we believe it's time to change the way clothing is produced and give a new meaning to Made in USA - creating the highest quality products while also creating quality American jobs.

We only knit a garment once someone orders it, meaning we never have stock or inventory. We produce what is needed when it is needed, with short delivery times due to efficient knitting and reduced post production. It's our goal to redefine the way clothing is made with an ethical, forward-thinking and value driven supply chain.

With that said, take a look at our new “Zero Waste Knitwear” collection, now available in our online shop.

The initial collection includes 5 versatile knit styles designed to be dressed-up or dressed-down, with everything from bespoke suits to swim trunks.

Here's three of the best-selling styles so far: 

The V-Neck Polo

The V-Neck Polo is an elegant polo shirt designed for style, comfort and versatility. It's soft, lightweight, easy to care for (yes, it's machine washable) and you can style it with virtually everything in your closet; from bespoke suits, jackets and trousers to casual chinos, jeans and even athleisure.

The Genteman's Tee

The Gentleman's Tee is soft, lightweight, easy to care for (yes, it's machine washable) and designed for maximum versatility. Think of it as a more elegant/sartorial t-shirt. One that you can style it with everything in your closet; from bespoke suits, jackets and trousers to casual chinos, jeans and even athleisure.

The Tailored Hoodie

The Tailored Hoodie is not your typical hooded sweatshirt. It's grown-up, sexy and elegant. I've always loved hoodies but could never find one that's lightweight, slim or fine enough to style under a tailored jacket or with a pair of trousers.

So we created the Tailored Hoodie, and it might be the most versatile garment we've ever made. It's soft, lightweight, easy to care for (yes, it's machine washable) and designed for maximum versatility. You can style it with everything in your closet; from bespoke suits, jackets and trousers to casual chinos, jeans and even athleisure. It's one of the only garments you can wear to the gym (I play basketball in mine regularly) and also wear for a date, a night out or a day at the office.

Thanks, as always, for reading.

Yours in style,

Dan Trepanier