11. Open Source Hardware - From Fibers to Fabric¶
Research & Ideation¶
I have always been intrigued by textiles and their material properties. This week, I am exploring the development of a DIY bottle cutter that can be used to generate filament for weaving. This tool is increasingly relevant 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. By creating a DIY bottle cutter, designers can 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. Instead of relying solely on industrial recycling systems which can be energy-intensive and geographically limited—designers can prototype closed-loop systems within studios, Fab Labs, and educational settings. This supports localized circular production, where waste generated in a community can be immediately repurposed into new textile forms. This tool also contributes to material literacy and innovation. By physically cutting and manipulating PET bottles into continuous strands, designers develop a first-hand understanding of material behavior, tensile strength, flexibility, and limitations. This hands-on engagement supports more informed material choices and enables experimentation with hybrid textiles that combine recycled filament with natural fibers, biomaterials, or smart textiles. In addition, DIY bottle cutters lower the barrier to experimentation and access. Because the tool can be inexpensive, easily fabricated, and adapted to different contexts, it is especially valuable for emerging designers, students, and under-resourced labs. This democratization of material production aligns with broader shifts toward open-source tools, transparent processes, and equity in design education.
Finally, the presence of DIY bottle cutters 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 final product, 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. Alongside this work, I am also exploring yarn twisting as a foundational step toward weaving. For this project, I am investigating the idea of creating or hacking a small-scale yarn twisting machine 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 exploration is informed 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 especially interested in how a hacked twisting system can function as both a tool and a learning instrument, one that enables experimentation with fiber blends, twist direction, ply structures, and recycled or repurposed materials. At a small scale, the machine becomes a platform for discovery rather than mass production. In this week’s research and prototyping, I am focusing on the basic mechanics of yarn twist and plying; examples of DIY and small-scale twisting tools; how twist level impacts strength, elasticity, and texture; opportunities for novelty or artistic yarn construction; and ways to adapt accessible parts using digital fabrication. Ultimately, my intention is to prototype a simple, adaptable twisting mechanism that encourages experimentation, documentation, and reflection. This project sits at the intersection of textile science, hands-on making, and creative inquiry that aligns with my broader interest in connecting material knowledge, innovation, and student-centered learning.
References & Inspiration¶
A few years ago, I took students to the MAGIC trade conference in Las Vegas, where I was introduced to REPREVE. REPREVE is a recycled performance fiber developed by Unifi, Inc. that transforms post-consumer plastic bottles and other recycled materials into sustainable polyester yarns and fabrics. These fibers are used globally by fashion, outdoor, and lifestyle brands and are designed to perform like traditional polyester while significantly reducing environmental impact. The concept of a traceable, branded recycled fiber immediately stood out to me, particularly in the context of large-scale textile production.
Later, I learned that Chick-fil-A had incorporated recycled plastic into their employee uniforms. Their red polo shirts are made using the equivalent of approximately 19 plastic bottles, while the blue-and-white striped shirts use about 9 bottles each. This initiative is part of the company’s broader sustainability and recycling efforts aimed at diverting plastic waste from landfills.
Photo courtesy of REPREVE
Photo courtesy of Chickfila
Other Major Retail Brands that Uses PET Recycled Bottles for fashion...¶
Adidas x Parley Adidas has become one of the most visible and influential brands using recycled PET (rPET) in fashion and performance wear, positioning sustainability as a core innovation strategy rather than a niche initiative. A major turning point in this work is its long-term collaboration with Parley for the Oceans, which focuses on intercepting plastic waste before it reaches marine ecosystems and transforming it into high-performance textile materials. Through the Adidas x Parley partnership, plastic waste collected from coastal regions and shorelines is processed into recycled PET yarns that are used in shoes, athletic apparel, and accessories. Many Parley shoes replace virgin polyester entirely with recycled PET, particularly in uppers made from knit or mesh constructions. In some footwear models, a single pair can contain the equivalent of up to 11 plastic bottles, demonstrating how waste can be recontextualized at scale.
Beyond Parley, Adidas has committed to broader sustainability goals, including the transition to 100% recycled polyester across its product lines where possible. Recycled PET is now used extensively in jerseys, training apparel, leggings, and outerwear, proving that recycled fibers can meet the brand’s strict standards for durability, breathability, moisture management, and performance. From a textile innovation perspective, Adidas’s use of rPET is significant because it integrates recycled materials into advanced manufacturing systems, such as knitted uppers, engineered meshes, and digitally optimized designs. This approach minimizes material waste while maximizing efficiency and product lifespan.
Photo from parley.com
The Northface The North Face is a leading outdoor apparel brand that incorporates recycled PET (rPET) from plastic bottles into a wide range of products, including jackets, insulation, backpacks, and performance gear. By transforming post-consumer bottles into recycled polyester fibers, the brand reduces dependence on virgin petroleum while maintaining the durability and performance required for outdoor use. Recycled PET is commonly used in fleece fabrics, outer shells, linings, and synthetic insulation, where warmth, lightweight construction, and resilience are essential. Many of The North Face’s insulated jackets and backpacks now contain significant percentages of recycled content, supporting the brand’s broader sustainability commitments. From a design and manufacturing perspective, The North Face demonstrates how recycled materials can be integrated into technical, high-wear products without sacrificing function. Their use of recycled bottles shows how sustainability can be embedded into everyday outdoor gear at scale, making rPET a practical and accessible material choice rather than a niche alternative.
Photo from northface.com
Tools¶
Drill
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 | ||
| 2 | 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. The images document the step-by-step process of transforming a plastic PET bottle into continuous filament for textile experimentation. The first images show the initial setup, where a clean plastic bottle is prepared and mounted on a simple DIY cutting base. Basic tools—such as clamps, a blade, and a guide—are used to stabilize the bottle and control strip width during cutting. As the bottle is rotated, it is cut into long, continuous plastic strands, visible in the subsequent images as coiled green filament. These strands demonstrate the potential of PET bottles to be repurposed into flexible material suitable for weaving, yarn twisting, or experimental textile construction. The final images show the accumulated filament, highlighting both the volume of material generated from a single bottle and the consistency of the cut. Together, the photos illustrate a low-tech, accessible workflow that converts post-consumer plastic waste into usable textile material, supporting hands-on material exploration and circular design practices.
My pictures are ...
Gallery¶
