Towards sustainable wearer-centered knitwear systems: a meso-level, investigation of comfort and structural preference in sustainable knitwear manufacturing

This study examines knitwear comfort through a systems lens, asking how construction choices in fully fashioned (FF) and seamless (SL) garments influence wearer performance that underpins longevity. In a meso-level wearer trial, 10 female participants rated pleasantness of fit (POF), discomfort and confidence across three range-of-motion (ROM) stances using Likert scales supplemented by open comments. While statistical analysis identified no significant differences in overall comfort ratings between FF and SL garments, integrated qualitative analysis revealed a clear structural trade-off with implications for sustainable design. FF garments provided dimensional stability in static postures but exhibited limited recovery following deformation, whereas SL garments accommodated movement more readily yet increased textile-to-skin contact during motion, before recovering more effectively post-movement. These findings demonstrate that comfort perception emerges from the interaction between structure and movement, rather than from construction type alone. Aligned with the Functional dimension of the FEA model, the study identifies region-specific optimisation as a pathway to reducing discomfort triggers, improving recovery, and extending use-phases. In this exploratory meso-level trial with 10 female participants, micro seam/contact mechanisms are linked to garment-level perception providing actionable guidance for efficient, minimal-waste manufacturing pathways that support comfort, attachment, and circular lifespans. Findings inform scalable, region-specific optimisations within sustainable knitwear systems.