10. Textile Scaffold¶
Research and Ideation
Textile scaffolds are structured frameworks created from woven, knitted, or nonwoven textile materials, often used in applications like tissue engineering, sustainable design, and architecture. They provide a supportive matrix for cell growth in biomedical applications, mimicking the extracellular matrix to aid in tissue regeneration or wound healing. These scaffolds can also be incorporated into fashion, wearable tech, or architectural designs, offering lightweight and versatile solutions. Made from materials such as natural fibers, synthetic polymers, or biopolymers, they are valued for their porosity, strength, and sometimes biodegradability, enabling eco-friendly and innovative uses across industries.
Textile formwork
Textile Formwork represents an exciting blend of design, technology, and material science. By using fabric as a mold for concrete or other materials, it makes it possible to construct intricate, lightweight forms that would be difficult to achieve with conventional methods. The inherent flexibility of textiles allows for the creation of complex and organic shapes, expanding the creative potential in architecture and design. This technique also supports sustainability, as it typically uses fewer materials, generates less waste, and promotes more efficient construction. Moreover, integrating textiles with varying textures and properties opens the door to multifunctional surfaces and groundbreaking structural innovations, redefining the limits of both design and engineering.
Fabric formwok with casting
Fabric formwork involves using flexible textile materials as molds for casting substances such as concrete, plaster, or bio-composites. This pliability enables the creation of smooth, organic shapes that are difficult to replicate with conventional rigid molds.
Materials
| Category | Purpose |
|---|---|
| Fabric Base | Forms the mold; its flexibility shapes the cast and defines surface texture |
| Yarns | Adds structure, texture, or interactive features to the casting |
| Casting Material | Solidifies to capture the shape and details defined by the fabric and yarns |
| Frame Structure | Holds the fabric in place, provides tension and desired geometry |
| Fastening Tools | Helps secure fabric and yarns during setup and casting process |
The recipe
| Component | Estimated Quantity | Purpose |
|---|---|---|
| Cotton fabric | 0.5 kg | Acts as the structural base for shaping the scaffold |
| Plaster of Paris (binder) | 1.5 kg | Main binding agent to solidify the form |
| Water | 700 ml | Mixed with plaster to form a smooth paste |
| Cotton yarn | 100 g | Added to create texture and support |
| Wooden frame | 1 unit (approx. 40Ă—40 cm) | Holds and stretches fabric during plaster application |
| Fastening tools (pins, clamps) | As needed | Keeps yarn and fabric taut and in position |
| Gloves and mask | 1 pair each | Safety while handling plaster and dust |
Steps overview
| Step | Action |
|---|---|
| 1 | Build a Frame – Create a simple structure to stretch the fabric over |
| 2 | Attach Fabric – Pull fabric taut over/around the frame |
| 3 | Wrap or Stitch Yarns – Add structure or texture with yarns |
| 4 | Pour Casting Material – Slowly pour plaster, concrete, or other materials |
| 5 | Let Cure – Allow the casting to harden completely |
| 6 | Remove – Take off the frame and peel away the fabric (or leave it embedded) |
For this assignment, I'm truly excited to dive into the technique of fabric formwork combined with casting. I plan to use yarn to sculpt the shape and introduce unique textures, allowing the soft materials to guide the design process. I'm particularly fascinated by how flexible fabrics and delicate yarns can produce organic, fluid, and expressive surfaces once the material hardens. This approach feels like a beautiful conversation between softness and strength, and I can't wait to see how the interplay of textures and forms will bring a dynamic, almost alive quality to the final piece.
Resulted Pieces¶
I thoroughly enjoyed this experiment as it was my first experience working with concrete, giving me the chance to explore new materials and techniques through direct, hands-on work. The use of fabric formwork and yarns revealed surprising possibilities, and I was intrigued by how the soft, pliable materials influenced the final shape of the casting. The process felt naturally exploratory and creative, which made it especially engaging. I’m looking forward to building on this approach and creating more pieces to uncover new shapes, textures, and artistic directions.
Molding using cotton
Inspiration
Inspired by Irina MyDIYLife's innovative cotton molding techniques, I see cotton not merely as a soft textile but as a versatile medium for crafting intricate forms. Her method of shaping cotton into detailed ornaments showcases the material's potential in sustainable and creative design. This approach motivates me to explore cotton's structural capabilities in my own projects, blending traditional craftsmanship with eco-friendly practices.
I began by designing a 3D model to serve as the base for my molding experiment using cotton. This process allowed me to apply the practical skills acquired during the course. The model I chose to create was a mini crochet hook cupboard, a functional and symbolic piece that reflects my work in textile craft. Designing the cupboard required integrating various sketch types and features within the modeling software, laying the groundwork for producing a detailed and precise mold. Once the sketch was complete, I used the extruded boss feature to give it depth and form, allowing the design to take shape in 3D.
After creating a fully defined sketch that divided the model into sections—forming compartments for storing my crochet hooks—I proceeded to extrude those sections, giving the design a clear structure and functional depth.
all the steps in solidworks was done. so I had to save my model in STL in order to proceed to the next phase of slicing.
Here is the file
I opened it in the slicing software for the setting I was going to use in 3D printer.
After printing the 3D cupboard mold, I moved on to the final stage of the experiment—shaping the cotton around the mold. Instead of placing the cotton inside, I carefully pressed and wrapped it around the outer surface of the printed cupboard. This approach allowed the cotton to take on the form and texture of the mold, resulting in a well-defined box shape.
Cotton Molding Recipe
| Component | Estimated Quantity | Purpose |
|---|---|---|
| Raw cotton fibers | 500 g | Base material to create the moldable pulp |
| Warm water | 0.5 liter | Softens and blends the cotton into a workable pulp |
| Liquid soap (binder) | 3 tablespoons | Acts as a binder to help cotton fibers stick together |
| Glycerin | 1 tablespoon | Adds flexibility to the final dried material |
| Molding cupboard | 1 unit (tray or shallow mold) | Used to shape and contain the material during drying |
Table step and description
| Step | Description |
|---|---|
| 1. Prepare Cotton | Use clean, raw cotton balls or fibers as the primary material. |
| 2. Create Cotton Pulp | Soak cotton in warm water until soft, then blend into a smooth pulp using a mixer or blender. |
| 3. Add Binders | Mix in natural binders like gelatin or cornstarch, and add glycerin or linseed oil for flexibility. |
| 4. Form the Material | Spread the cotton pulp onto a mold or flat surface, press gently to remove excess water, and shape. |
| 5. Drying and Curing | Let the shaped cotton dry completely, pressing if needed. Treat with wax or oil for durability. |
| 6. Molding | Mold or refine the dried material by hand or with a shaping tool for the final form. |
Final result¶
Crystallization with Alum
Crystallization using alum (aluminum potassium sulfate) is a simple and visually striking process that produces large, clear or colored crystals. It’s commonly used in science demonstrations, crafts, and textile or fashion experiments (e.g. for texture or embellishment).
🧪 What is Alum?¶
Alum is a double sulfate salt, usually KAl(SO₄)₂·12H₂O. It dissolves easily in water and forms crystals as the solution cools or evaporates.
Recipe¶
For the crystallization process, I dissolved 30 grams of alum in 180 milliliters of warm water. As the solution gradually cools, crystals start to develop, forming clear and visually appealing structures.
🧫 Crystallization Process:¶
To begin the crystallization process, I boiled water and slowly added alum powder, stirring continuously until no more could dissolve. This gave me a saturated solution, essential for forming crystals. I let the solution cool naturally at room temperature, and soon I noticed tiny crystals starting to form on their own.
From these, I selected one well-shaped crystal to serve as my seed. I tied it to a string and carefully suspended it in a new batch of the saturated solution. I made sure to leave it undisturbed for several days. Over time, I observed the crystal gradually growing, layer by layer, taking on a clear, angular shape. The entire process was simple but fascinating to watch.
Resulted crystals¶
Crystals have beautifully formed on a crocheted flower, creating an intricate and mesmerizing effect that enhances the delicate craftsmanship of the piece. The process of crystal formation involved carefully applying a solution to the crocheted threads, allowing the crystals to grow over time and settle onto the fibers. The result is stunning—each petal now sparkles with a unique, geometric pattern of crystals that complement the soft texture of the yarn. The contrast between the smooth yarn and the sharp, shimmering crystals adds depth and elegance to the flower, making it look like a piece of nature’s art. This fusion of textile and crystal not only showcases the innovative potential of combining different materials but also elevates the crochet work into something extraordinary, blending craftsmanship with natural beauty in a way that is both striking and sophisticated.
CNC Milling Machine
A CNC (Computer Numerical Control) milling machine is a highly automated tool designed for precision machining of materials like metals, plastics, wood, or composites. By using computer-controlled commands, it guides a rotating cutting tool along multiple axes—commonly X, Y, and Z—to shape, cut, or drill materials into specific forms with exceptional accuracy. Widely employed in manufacturing industries such as aerospace, automotive, jewelry, and prototyping, CNC milling machines are essential to modern production. They combine flexibility, precision, and automation, significantly enhancing efficiency and enabling the creation of complex designs with consistent quality. For more information about those machines click here Review on CNC
Inspiration
Textile scaffolding enables innovative design across fashion, architecture, and healthcare. In fashion, it supports modular, customizable garments. In architecture, it leads to lightweight, flexible structures like fabric pavilions. It’s also used in medicine for tissue scaffolds and healing materials.
A great example is tensile fabric structures, such as those in stadiums or pavilions. These stretch fabric over frames to create strong, adaptable spaces—like the Beijing National Stadium. This approach blends textile flexibility with structural strength, showing the broad potential of textile scaffolding.
Molding a christmas tree using CNC
Step 1: Designing the 3D Christmas Tree in SolidWorks
I began the project by modeling the Christmas tree in SolidWorks, focusing on creating a form that would both look festive and work well as a CNC-machined mold. Starting with a simple conical base for the main structure, I then added tiered triangular branches that gradually decreased in size as they moved upward, giving the tree a natural, layered appearance.
SolidWorks gave me the precision I needed to incorporate symmetry and accurate geometries, especially since the model would later be machined. I used fillets and extruded cuts to sculpt subtle textures and depth into the branches—small ridges meant to mimic pine needles. To complete the design, I added a star at the top and engraved circular decorations directly into the surface to avoid additional post-processing.
Once the tree design was complete, I exported the model as an STL file, ready for toolpath generation and CNC machining.
CLICK HERE to get my christmas tree Stl. file
Step 2: Preparing the Model for 5-Axis CNC Machining
Instead of using Fusion 360, I imported the STL file into ShopBot-compatible CAM software (such as Aspire, RhinoCAM, or another CAM tool that supports 5-axis machining). Because I was using a 5-axis ShopBot, I had much more flexibility in terms of undercuts, smoother finishes, and efficient carving from all angles.
I selected wood as my material—ideal for clean cuts and warm visual aesthetics. Tooling setup included:
A flat end mill for roughing passes to remove large volumes of material quickly.
A ball-nose end mill for finishing passes, perfect for carving out the fine details like the decorative texture and star contours.
I defined the roughing strategy to remove most of the block’s volume with broader strokes, then configured a multi-axis finishing strategy to capture the full geometry with fine detail from multiple angles. Simulations were crucial here, as I needed to ensure the machine would avoid collisions while still accessing every necessary surface. Once satisfied, I generated the G-code tailored for the 5-axis ShopBot.
Step 3: CNC Machine Setup and Execution
I mounted the wooden block onto the ShopBot’s bed, securing it firmly using clamps and ensuring it wouldn't shift during the cutting process. Since the ShopBot offers dynamic 5-axis movement, it was important to confirm that the entire block was accessible from multiple orientations.
I calibrated the X, Y, and Z axes—placing the origin at the bottom-left corner of the block for X and Y, and using the surface of the material for Z. This ensured that my machining paths aligned perfectly with the model's coordinate system.
Before starting the job, I installed the correct tool bits, loaded the G-code into the ShopBot controller, and performed a dry run to make sure everything was in place. Once confirmed, I initiated the cut. The machine first completed the roughing pass, followed by a multi-directional finishing pass that revealed all the intricate textures and festive details I had built into the SolidWorks model.
Conclusion: Lessons from an Incomplete CNC Molding
Although the design process was smooth and the toolpaths were well-prepared, the final outcome didn’t go as planned. During the CNC machining phase, the ShopBot encountered a serious mechanical issue, which caused the machine to halt abruptly before completing the finishing pass. As a result, the Christmas tree mold was left incomplete, with several details—especially on the branches and top star—missing or poorly defined. This unexpected setback highlighted the importance of regular maintenance and monitoring of high-precision equipment. While it was disappointing not to achieve the fully finished mold, the experience deepened my understanding of the limitations and fragility of CNC systems, especially in complex 5-axis operations. It also reinforced the value of preparation, adaptability, and learning from failures as part of the digital fabrication journey.