ExoFabric
A re-moldable textile system for creating customized soft goods and wearable applications through machine embroidery.
ExoFabric, a re-moldable fabric system for customized soft good and wearable applications. ExoFabric is created by embedding thermoplastic threads into fabric through computerized embroidery to allow for tunability between rigid plastic and conformable fabric. We defined a library of design primitives to enable geometric formability, stiffness, and stretchability by identifying suitable fabrics, threads, embroidery parameters, and machine limitations. To facilitate practical applications, we demonstrated design methods for linking parameters to application requirements, showcasing form-fitting wearables, structural support, and shape-changeable furniture for repeatable or one-time customization.
Team: Rosalie Lin, Aditi Maheshwari, Jung Wook Park, Andreea Danielescu
Accenture Labs, Future Technologies Group
Motivation
Fabric has been a fundamental part of human life for thousands of years, providing comfort, protection, and aesthetic expression. While modern advancements have enhanced fabric’s functionality, it remains static and unchangeable, failing to adapt to our evolving body shapes and preferences. This lack of adaptability can lead to unsustainable practices, as consumers often buy more items to meet their changing needs.
Material working principle: Leveraging thermoplastic's re-moldability
Thermoplastic, the core material enabling re-moldability, can be easily formed through the application of heat and mold. In this work, we chose to work nylon monofilament with Tg ranging between 47°C to 57°C (approximately 117°F to 135°F) to ensure the temperature is low enough to prevent users from being harmed during the molding process while prioritizing textile integration and tool accessibility within the HCI community and the textile industry.
Fabrication parameters & ExoFabric affordance
The desired characteristics of ExoFabric include re-moldability, geometrical formability, stiffness, and stretchability. We further breakdown each affordance and link them to the relevant fabrication parameters, providing design guidelines for creating ExoFabric. These parameters include the material properties of thermoplastics, the quantity and direction of thermoplastics, the types of fabric, and the molding tools used.
Systematically evaluating the optimal embroidery configuration across stiffness, geometrical formability, and stretchability
The desired characteristics of ExoFabric include re-moldability, geometrical formability, stiffness, and stretchability. We further breakdown each affordance and link them to the relevant fabrication parameters, providing design guidelines for creating ExoFabric. These parameters include the material properties of thermoplastics, the quantity and direction of thermoplastics, the types of fabric, and the molding tools used.
Stiffness evaluation via Compression testing
We performed compression tests on the nine embroidery configura- tions across two fabric types to identify the optimal ExoFabric combinations that can maintain their desired shape under applied load
Geometrical formability evaluation via molding curvature difference
Formability, or the ability to conform to the shape of intended molds, is another critical factor in our evaluation as it facilitates the molding of ExoFabric into the desired shape. We assessed formability by observing the shape discrepancy between the molded fabric and the mold, and by evaluating the durability of the fabrication formation over time without external force.
Stretchability evaluation via Tensile testing
In the stretchability evaluation, the results suggest that both line spacing and stitch spacing work together to influence the stretchability of the fabric. Larger line spacings combined with larger stitch spacing results in the most flexible configurations, while smaller line spacings and smaller stitch spacing leading to reduced stretchability.
Application 1: Rigid finger splint
We demonstrated ExoFabric as a finger splint, highlighting its potential for supporting structured gear and tunable rigidity. The fiber orientation followed the finger’s bending direction to ensure it withstands forces from bent finger parts while the thermoplastic is located on the top side of the finger to provide the maximum restricting force.
Application 2: Customizable bras
To envision more customizable wearables, we demonstrated a shape-changing bra that best performs formability and stretchability. The radial pattern is chose to allow for doubly curved geometry. We also conducted the washability test to validate the prototype can perform the intended function after soaking in water for a few hours and air drying for a few hours.
Application 3: Shape-changeable lamp shade
We applied ExoFabric to lighting, demonstrating its potential to adapt to ever-changing styles without the need to replace the lamp shade. This application allows us to determine the feasibility of using ExoFabric in mild heat-generating devices, while ensuring its stability under such conditions. Additionally, we aimed to assess how easily the lamp shade’s shape could be altered, as it may be adjusted according to the ambiance or to personal preference.
