Abstract: A method for forming a molded garment is provided. The method includes positioning an assembly of material between a first heated mold element and a second heated mold element, moving the first and second heated mold elements in relation to one another to laminate the assembly of material into a laminated assembly; moving a third heated mold element through the first heated mold element into contact with the laminated assembly so that the third heated mold element shapes a portion of the laminated assembly; and causing the first and second heated mold elements to trim fabric from the laminated to define the molded garment.

Abstract: A method is provided for forming a garment, including providing a fabric layer having sonically weldable material, the fabric layer having an inner surface and at least one opening region, the opening region having a periphery and an outer free edge, placing an elastic edge band having sonically weldable material around the entire periphery of the opening region, the edge band having first and second free edges and an inner surface, securing the first free edge of the edge band to the outer free edge of the opening region with a subsonic or ultrasonic edge weld to form a finished seamless edge along the opening region, and activating an adhesive along more than half of the inner surface of the edge band to secure the edge band and second free edge to the inner surface of the fabric layer.

Abstract: A method is provided for molding a breast-receiving cup for a garment, comprising laminating a support fabric to a lofted material to form a lofted assembly, positioning the lofted assembly in a molding apparatus having a first mold with a projecting element and a second mold having a recessed element, and closing together the first mold and the second mold while maintaining a uniform preset gap between the projecting element and the recessed element to form a molded lofted assembly in the shape of a breast-receiving cup.

Abstract: Methods of molding a non-woven fabric are provided. The methods include selecting a non-woven fabric having a web of fibers having a uniform fiber orientation in all directions, compressing the non-woven fabric between a top mold and a bottom mold, and maintaining the non-woven fabric between the top and bottom molds for a predetermined dwell time to define a molded depth and a molded diameter in the non-woven fabric.

Abstract: A method is provided for forming a garment, including providing a fabric layer having sonically weldable material, the fabric layer having an inner surface and at least one opening region, the opening region having a periphery and an outer free edge, placing an elastic edge band having sonically weldable material around the entire periphery of the opening region, the edge band having first and second free edges and an inner surface, securing the first free edge of the edge band to the outer free edge of the opening region with a subsonic or ultrasonic edge weld to form a finished seamless edge along the opening region, and activating an adhesive along more than half of the inner surface of the edge band to secure the edge band and second free edge to the inner surface of the fabric layer.

Abstract: Methods of molding a non-woven fabric are provided. The methods include selecting a non-woven fabric having a web of fibers having a uniform fiber orientation in all directions, compressing the non-woven fabric between a top mold and a bottom mold, and maintaining the non-woven fabric between the top and bottom molds for a predetermined dwell time to define a molded depth and a molded diameter in the non-woven fabric.

Abstract: A method is provided for forming a garment, including providing a fabric layer having sonically weldable material, the fabric layer having an inner surface and at least one opening region, the opening region having a periphery and an outer free edge, placing an elastic edge band having sonically weldable material around the entire periphery of the opening region, the edge band having first and second free edges and an inner surface, securing the first free edge of the edge band to the outer free edge of the opening region with a subsonic or ultrasonic edge weld to form a finished seamless edge along the opening region, and activating an adhesive along more than half of the inner surface of the edge band to secure the edge band and second free edge to the inner surface of the fabric layer.

Abstract: A garment having a fabric layer and an edge band is provided. The edge band and the fabric layer each include a sonically weldable material. The garment has a sonic edge weld securing the edge band to the fabric layer along a cut edge of the garment and an adhesive securing the edge band to the fabric layer. During manufacture, the edge band is placed on the fabric layer, sonic energy is applied so that the fabric layer and the edge band are simultaneously trimmed along a cut edge and welded to one another along the cut edge, and an adhesive between the fabric layer and the edge band is activated to adhere the edge band to the fabric layer.

Abstract: Methods of molding a non-woven fabric are provided. The methods include selecting a non-woven fabric having a web of randomly disbursed fibers, compressing the non-woven fabric between a top mold and a bottom mold, and maintaining the non-woven fabric between the top and bottom molds for a predetermined dwell time to define a molded depth and a molded diameter in the non-woven fabric. In some embodiments, the method includes exposing the non-woven fabric to mechanical agitation. In other embodiments, the method includes selecting the top and bottom molds to have a depth that is larger than the molded depth by about 30 to about 50 percent and a diameter that us larger than the molded diameter by less than about 10 percent.

Abstract: A pad for a brassiere has a first layer; a second layer; and an intermediate layer between the first layer and the second layer. The first layer, the second layer and the intermediate layer are connected at predetermined locations to form a first plurality of depressions on the first layer and a second plurality of depressions on the second layer. The brassiere has a pair of back panels, a pair of shoulder straps, and a pair of breast receiving cups. Each of the pair of breast receiving cups has a first layer; a second layer; and an intermediate layer between the first layer and the second layer. The first layer, the second layer and the intermediate layer are connected to form a first plurality of depressions on said first layer and a second plurality of depressions on said second layer.

Abstract: A method is provided for molding a breast-receiving cup for a garment, comprising laminating a support fabric to a lofted material to form a lofted assembly, positioning the lofted assembly in a molding apparatus having a first mold with a projecting element and a second mold having a recessed element, and closing together the first mold and the second mold while maintaining a uniform preset gap between the projecting element and the recessed element to form a molded lofted assembly in the shape of a breast-receiving cup.

Abstract: An upper support garment having a back portion comprising an inner fabric layer, an outer fabric layer, and an adhesive applied between the inner and outer fabric layers to connect together the inner and outer fabric layers. The inner fabric layer has a pair of cutouts therethrough and the adhesive layer has an identical pair of cutouts. The pair of cutouts of the inner fabric layer are positioned to correspond to the back muscles of a wearer.

Abstract: A method for making a garment having a lofted assembly having an outer support layer and garment so produced are provided. The method includes the steps of positioning a support fabric on a lofted material; sewing the support fabric to the lofted material to form a lofted assembly; positioning the lofted assembly in a molding apparatus having at least a first mold and a second mold, closing together the first mold and the second mold thereby sandwiching the lofted assembly therebetween and while maintaining a uniform preset gap between said first mold and the second mold so that the inherent loft characteristics of the lofted assembly are substantially preserved after pressure and/or heat are applied.

Abstract: A method for molding a lofted assembly having a lofted material and a laminated nylon support material the garment produced are provided. The method includes the steps of positioning a support fabric on a lofted material; laminating the support fabric to the lofted material to form a lofted assembly; positioning the lofted assembly in a molding apparatus having at least a first mold and a second mold, closing together the first mold and the second mold thereby sandwiching the lofted assembly therebetween and while maintaining a uniform preset gap between said first mold and the second mold so that the inherent loft characteristics of the lofted assembly are substantially preserved.

Abstract: A method for making a garment having a lofted assembly having an inner laminated support fabric and an outer panel and the garment produced are provided. The method includes the steps of positioning a support fabric on a lofted material; laminating the support fabric to the lofted material to form a lofted assembly; positioning the lofted assembly in a molding apparatus having at least a first mold and a second mold, closing together the first mold and the second mold thereby sandwiching the lofted assembly therebetween and while maintaining a uniform preset gap between said first mold and the second mold so that the inherent loft characteristics of the lofted assembly are substantially preserved. Then the outer panel is stitched to an outer side of said lofted assembly.

Abstract: A pad for a brassiere has a first layer; a second layer; and an intermediate layer between the first layer and the second layer. The first layer, the second layer and the intermediate layer are connected at predetermined locations to form a first plurality of depressions on the first layer and a second plurality of depressions on the second layer. The brassiere has a pair of back panels, a pair of shoulder straps, and a pair of breast receiving cups. Each of the pair of breast receiving cups has a first layer; a second layer; and an intermediate layer between the first layer and the second layer. The first layer, the second layer and the intermediate layer are connected to form a first plurality of depressions on said first layer and a second plurality of depressions on said second layer.

Abstract: An upper support garment having a back portion comprising an inner fabric layer, an outer fabric layer, and an adhesive applied between the inner and outer fabric layers to connect together the inner and outer fabric layers. The inner fabric layer has a pair of cutouts therethrough and the adhesive layer has an identical pair of cutouts. The pair of cutouts of the inner fabric layer are positioned to correspond to the back muscles of a wearer.