Systems and methods for morphable embroidery-based textiles

NU 2024-235

INVENTORS

• Jian Cao*
• Marisa Bisram
• Yunyun Wu

SHORT DESCRIPTION

This technology merges kirigami-inspired design principles with digital embroidery to create customizable 3D textile wearables that eliminate the need for post-processing cuts, reduce material waste, and increase production speed. 

BACKGROUND

Manufacturers and researchers have long grappled with the difficulty of producing textiles that seamlessly conform to three-dimensional shapes while maintaining both durability and flexibility. Traditional methods often involve labor-intensive cutting, stitching, or bonding processes that increase production time and material waste, and they can limit design versatility. Achieving programmable mechanical properties—such as tunable stiffness or targeted stretch—presents additional hurdles, as current approaches tend to rely on complex structural modifications that may require specialized equipment or post-processing steps. 

ABSTRACT

This method merges kirigami-inspired design principles with digital embroidery to create customizable 3D textile wearables that eliminate the need for post-processing cuts, reduce material waste, and increase production speed. Utilizing CAD software to design shape vectors, these are converted into stitch commands using embroidery software. The innovative method employs a stabilizer that washes away, leaving a "self-stable" structure made solely of stitch material, similar in feel to conventional textiles. The embroidery patterns facilitate the formation of 3D morphable shapes, offering a new dimension in textile manufacturing.

APPLICATIONS

• Morphable Structures
  • Enables textiles to form into various 3D shapes.
• Smart E-Textiles
  • Integrates digital embroidery for functional wearables.
• Textile Manufacturing
  • Streamlines processes with reduced waste and increased customization.

ADVANTAGES

• Versatility for 3D conforming shapes
  • Kirigami-inspired design in embroidered textiles readily adapts to varied 3D geometries with minimal tooling.
• Enhanced customization and design control
  •  Offers fine-tuned control over slit placement, stitch density, and shape.
• Faster production times
  •  Leverages commercially-available digital embroidery machines for quicker fabrication of 3D textiles.
• Greater mechanical integrity and adjustability
  • Targeted reduction in stiffness and controlled stretchability.

PUBLICATIONS

Jian Cao et al, "Published in: ASME 2024 19th International Manufacturing Science and Engineering Conference", June 17–21, 2024.

IP STATUS

Patent Pending