Carnegie Mellon University Researchers Develop Innovative Flat-to-Shape Objects Using Sewing Technology
Researchers from Carnegie Mellon University’s Human Computer Interaction Institute (HCII) and Robotics Institute (RI) have unveiled a groundbreaking method for creating functional flat-to-shape objects with the help of a computer-controlled sewing machine.
The team behind this project includes Sapna Tayal, a talented undergraduate student in the School of Design, along with Lea Albaugh, Mark Stehlik postdoctoral teaching fellow at HCII, James McCann, an associate professor in RI, and Scott E. Hudson, a distinguished professor and associate department head for education in HCII.
The term “flat-to-shape” refers to objects that can transition from a flat sheet to a three-dimensional form through techniques like bending, folding, or assembling interconnected parts. While previous methods have utilized flat-to-shape processes on a small scale to expedite construction time on 3D printers and laser cutters, manual assembly was often required, making scaling up challenging. The team at CMU saw an opportunity to enhance these techniques and develop a method for producing furniture-sized, functional objects that are quick to deploy.
Albaugh highlighted the accessibility of sewing machines as a fabrication technology, noting their computational control capabilities that unlock various fabrication possibilities. The team repurposed a CNC sewing machine to sew at a larger scale, a departure from its traditional use in making quilted blankets.
The team’s innovative method involves stitching pockets between layers of fabric using the sewing machine, with stiff panels inserted into these pockets. Different fabric types can be employed, ranging from muslin for heavy-duty applications to more delicate fabrics for decorative purposes. This approach allows for customization on a panel-by-panel basis to cater to the specific requirements of each object.
The researchers showcased how the choice of materials can support a range of functional objectives, such as using thicker plywood for a chair capable of supporting human weight and incorporating custom LED panels with sheer fabric for a functional lamp. Furthermore, additional mechanisms like cords, magnets, and hook-and-loop fasteners can be integrated to guide and stabilize the transition from flat to shape.
Tayal expressed her excitement about the project, describing it as a unique opportunity to explore a new fabrication space through material experimentation and hands-on creation. The team’s novel method enabled them to achieve their objective of crafting items large enough for full-body human interactions, such as sitting, wearing, or carrying, while remaining portable and adaptable to various settings.
In their paper titled “Creating Furniture-Scale Deployable Objects with a Computer-Controlled Sewing Machine,” the researchers detailed a collection of functional flat-to-shape artifacts produced using their technique, including a side table, backpack, chair, and lamp. Each object featured distinct variations of inserting rigid panels within flexible fabric sheets, showcasing the versatility of their approach. The paper was accepted for presentation at the 2025 Conference on Human Factors in Computing Systems (CHI).
The project not only garnered recognition within the academic community but also earned Tayal the Industrial Designers Society of America (IDSA) Student Merit Award for the district level round.
For more information on this innovative fabrication method and to access the full paper, visit Sapna Tayal’s website. The research paper is also available for reference with a DOI link provided for further exploration.
This research breakthrough represents a significant advancement in the field of fabricating flat-to-shape objects, offering a practical and efficient approach to creating functional items on a larger scale. Carnegie Mellon University continues to lead the way in pioneering research that combines technology and design to push the boundaries of innovation.
Source: Carnegie Mellon University.
