Researchers at Carnegie Mellon University‘s Human-Computer Interaction Institute (HCII) and Robotics Institute (RI) have developed an innovative fabrication method that transforms flat sheets into three-dimensional, functional objects using a computer-controlled sewing machine. This pioneering technique has significant implications for product design, interior design, fashion, and even packaging innovation, particularly in sustainable and adaptable materials.

The project team, including design student Sapna Tayal, postdoctoral teaching fellow Lea Albaugh, associate professor James McCann, and professor Scott E. Hudson, leveraged the capabilities of CNC (computer numerical control) sewing machines—commonly used for quilting—to create larger, deployable structures quickly and efficiently.

Flat-to-Shape Fabrication
“Flat-to-shape” refers to objects that begin as flat textiles and transform into three-dimensional forms through folding, bending, or assembly. Methods employing 3D printing or laser cutting have shown flat-to-shape capabilities but often require labor-intensive manual assembly and struggle with scaling for larger objects. The Carnegie Mellon researchers’ approach overcomes these limitations by using an accessible and scalable technology: the sewing machine.

By stitching pockets between fabric layers and inserting rigid panels—such as plywood or composite materials—the team created lightweight, portable items that maintain strength and functionality. The method allows for significant material customization; muslin offers a robust structure, while more delicate fabrics add aesthetic qualities. Moreover, each panel within a structure can feature different materials tailored to specific performance needs.

Applications and Material Innovations
The versatility of this technique was demonstrated through various prototypes, including a chair capable of supporting human weight (using thicker plywood panels) and a lamp incorporating sheer fabrics and integrated LED panels. Additionally, flat-to-shape transitions were enhanced with cords, magnets, and hook-and-loop fasteners to stabilize and guide transformations.

This approach not only presents new opportunities for sustainable material use—through lightweight, durable, and potentially biobased or recycled textiles—but also significantly reduces the material waste and energy associated with traditional 3D construction methods. Its modularity and portability make it particularly attractive for applications where adaptability and space efficiency are critical.

Through their paper, Creating Furniture-Scale Deployable Objects with a Computer-Controlled Sewing Machine, the team presents a portfolio including a side table, a backpack, a chair, and a lamp—each showcasing variations on the theme of integrating rigid and flexible materials.

Source: Carnegie Mellon University
Photos: Carnegie Mellon University / Sapna Tayal