11. Open Source Hardware - From Fibers to Fabric¶

Research & Ideation¶

I have always been intridge with textiles and its properties. This week, I will look at the development of a DIY bottle cutter that can by used for weaving. This will hold growing significance within the textile and fashion industry as designers and manufacturers confront the environmental impact of synthetic textiles and plastic waste. Polyethylene terephthalate (PET), the material used in most beverage bottles, is the same polymer base used in polyester fiber production. Creating a DIY bottle cutter allows designers to directly access and reprocess this material at a local, human scale, transforming post-consumer waste into functional textile filament.

From an industry perspective, DIY bottle cutters represent a decentralized approach to material sourcing. Rather than relying solely on large-scale industrial recycling systems, which are energy-intensive and geographically limited, designers can prototype closed-loop systems within studios, Fab Labs, and educational settings. This capability encourages localized circular production, where waste generated in a community can be immediately repurposed into new textile forms.

The tool also plays an important role in material literacy and innovation. By physically cutting and manipulating PET bottles into continuous strands, designers gain firsthand understanding of material behavior, tensile strength, flexibility, and limitations—knowledge that is often abstracted away in conventional textile supply chains. This hands-on engagement fosters more informed material choices and supports the development of hybrid textiles, combining recycled plastic filament with natural fibers, bio-materials, or smart textiles.

In addition, DIY bottle cutters lower the barrier to experimentation and access. The tool is inexpensive, easily fabricated, and adaptable, making it valuable for emerging designers, students, and under-resourced labs. This democratization of material production supports equity in design education and aligns with industry shifts toward open-source tools and transparent processes.

Finally, the presence of DIY bottle cutters in the industry signals a cultural shift toward process-driven, value-based design. The act of visibly transforming waste into textile material becomes part of the narrative of the product itself, offering consumers a tangible story of sustainability, responsibility, and innovation. In this way, the DIY bottle cutter is not just a tool—it is a catalyst for rethinking how textiles are sourced, produced, and valued in the future of fashion.

This week, I will look at the twisting for yarns that can eventually be woven into fabric. For this project, I am exploring the idea of creating or hacking a small-scale yarn twisting machine as a way to better understand how yarn structure, twist, and material behavior influence textile performance and aesthetics. Yarn twisting is one of the most fundamental processes in textile production, yet it is often hidden within industrial systems and rarely experienced hands-on at the maker level. My goal is to bring this process into a creative, experimental, and educational context.

This project is inspired by my background in textile science, my interest in material experimentation, and my ongoing work with students in learning environments such as the NCCU Fab Lab. I am particularly motivated by the potential of a hacked or modified twisting system to function not only as a tool, but as a learning instrument — one that allows users to experiment with fiber blends, twist direction, ply structures, and recycled or repurposed materials. By working at a small scale, the machine becomes a platform for discovery rather than mass production.

In this exploration, I am researching: • basic mechanics of yarn twist and ply systems • examples of DIY and small-scale twisting tools • how twist level affects strength, elasticity, and texture • possibilities for novelty or artistic yarn construction • ways to adapt mechanisms using accessible parts and digital fabrication

My intention is to prototype a simple, adaptable twisting mechanism that encourages experimentation, documentation, and reflection. Ultimately, this project sits at the intersection of textile science, hands-on making, and creative inquiry — aligning with my broader interest in connecting material knowledge, innovation, and student-centered learning.

References & Inspiration¶

A few years ago, I took some students to a MAGIC conference in Las Vegas. At the conference, I was introduced to a company called REPREVE. REPREVE is a recycled performance fiber created by Unifi, Inc. that transforms post-consumer plastic bottles and other recycled materials into sustainable polyester yarns and fabrics used by fashion, outdoor gear, and lifestyle brands worldwide. It’s a traceable, branded recycled fiber designed to perform like traditional polyester while reducing environmental impact. This was very interesting to me.

Later I saw that Chick-fil-a create their uniforms from water bottles. About 19 bottles for used for the red polo and 9 for a blue-and-white striped one. This initiative is part of their recycling efforts to keep plastic out of landfills.

Two images side-by-side

Photo courtesy of REPREVE

Pholto courtesy of Chickfila

Other Major Retail Brands that Uses PET Recycled Bottles for fashion...

Patagonia: Outdoor apparel pioneer using recycled polyester from plastic bottles; a large portion of their fleece and other fabrics are made from PET bottle–derived fibers.

Girlfriend Collective: Popular activewear brand that uses recycled materials, including plastic bottles, in leggings, sports bras, and tops.

Adidas (Parley): Collaboration with Parley for the Oceans turns ocean and plastic waste (including bottles) into shoes, apparel, and accessories.

Rothy’s: Known for knitted shoes and bags made from thread spun from recycled plastic bottles.

Last Bottle Clothing: A smaller sustainable brand that makes apparel from 100% recycled and recyclable materials, specifically diverting plastics from waste streams.

Tools¶

Scissors Drill

BoM example¶

Materials¶

Qty	Description	Price	Link	Notes
1	Metal sharpener	$2.99	http://hobbylobby.com
1	Wood block	$3.99	http://hobbylobby.com
1	Dowel			already own
1	2 liter soda bottle	$1.25	http://dollartree
1	Super glue			already own

Process¶

The blade was taken loose and turned upside down and replaced in the holder. The holder was super glued to the wooden block. A hole was drilled to the right of the holder to place the dowel. The 2 liter bottles were cut across the bottom to prep for shredding. The bottom of the bottle was placed on an angle under the top part of the blade and pulled to start the shredding.

My pictures are ...