Deliverables¶
The Booklet¶
The main deliverable of the project is the Inflatable Textiles Booklet, a physical and digital publication designed as a reference guide for makers, students, and researchers.
The planning and fabrication of the booklet was done trhough the following timeline:
The booklet compiles:
- Background research on inflatable textiles
- Material exploration and benchmarks
- Fabrication methods and sealing techniques
- Experimental results and observations
- Fabrication parameters for different machines
The modular structure of the booklet allows new samples and experiments to be incorporated over time, transforming it into a living archive of inflatable textile research.
Material sample library¶
A collection of physical material samples was developed to document how different materials behave when used for inflatable textile fabrication.
The sample library includes:
- Plastic films
- Hybrid textile materials
- Recycled packaging materials
- Experimental laminated structures
Each sample documents: * Material type * Fabrication method * Sealing parameters * Observed performance
This library allows readers to compare materials and understand their behavior when inflated.
Inflatable textiles protoypes¶
A series of inflatable prototypes were fabricated to test different design strategies and fabrication methods.
These prototypes explore:
- Seam geometries
- Chamber structures
- Air retention behavior
- Structural response when inflated
The prototypes serve as practical demonstrations of the techniques described in the booklet.
Fabrication files and parameters¶
To support distributed replication of the project, all digital fabrication files are included.
These files include:
Laser cutting files for the booklet structure Printable page templates Inflatable pattern files Experimental sample geometries
All files are designed to be compatible with common FabLab tools and workflows.
The project also provides detailed documentation of the fabrication processes used during the experiments.
This includes:
- Laser sealing parameters
- Thermal sealing using a 3D printer hot end
- Material testing procedures
- Assembly instructions
By documenting the parameters and workflows, the project enables other makers to replicate and expand the experiments in their own labs.
Experimentation and documentation¶
All research, experiments, and results are documented and shared as open knowledge.
The documentation includes:
- Experimental observations
- Successful and failed tests
- Fabrication guidelines
- Recommendations for further exploration
This open documentation encourages the community to continue expanding the research on inflatable textiles.
The experimentation for the different machines and materials was documented as it follows:
- Thermal sealing using Laser
- Thermal sealing using the 3D printer hotend
- Thermal sealing using the Hot iron press with parchment paper sandwiched
For each material, different sealing parameters such as temperature, pressure, and time were tested. The goal was not only to determine whether a material could be sealed, but also to identify reliable fabrication strategies that could be easily replicated by students or makers.
These experiments resulted in a collection of inflatable samples that document the relationship between material properties and sealing techniques.
Laser cutter sealing¶
For this process we are using 3 different patterns for inflatable chambers on the materials. The parameters on each are different and listed, and the key for a clean fusing is to have both sheets as close together as possible, it is possible to use liquid, like water or hairspray, so the sheets stick together better. Some plastic bags are very tightly packed so it is useful for this process. Static electricity can also be a powerful ally, as rubbing the plastic on one's hair can create enough attraction between the sheets. For this process we can't use any PVC as it can produce toxic chlorine gases when it burns. With that in mind, the results for the rest of the materials are as follows:
LDPE ★★☆☆☆¶
- Machine: Laser Cutter
- Material: LDPE Plastic Film
- Did it work?: Yes
- Layer configuration: 2 layers
Sealing¶
- Power: 30%
- Speed: 200 mm/min
- Offsets: 3
- Fill: No
Cutting¶
- Power: 40%
- Speed: 100 mm/min
- Offsets: 1
- Fill: No
Chip's bag ☆☆☆☆☆¶
- Machine: Laser Cutter
- Material: Polypropilene + aluminium film + Polyethylene
- Did it work?: No
- Layer configuration: 2 layers
Sealing¶
- Power: 40%
- Speed: 150 mm/min
- Offsets: 3
- Fill: No
Cutting¶
- Power: 60%
- Speed: 100 mm/min
- Offsets: 1
- Fill: No
Ziploc bag ★★★☆☆¶
- Machine: Laser Cutter
- Material: Polyethylene film
- Did it work?: Yes
- Layer configuration: 2 layers
Sealing¶
- Power: 20%
- Speed: 200 mm/min
- Offsets: 3
- Fill: No
Cutting¶
- Power: 35%
- Speed: 100 mm/min
- Offsets: 1
- Fill: No
RipStop ☆☆☆☆☆¶
- Machine: Laser Cutter
- Material: RipStop
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Power: 65%
- Speed: 100 mm/min
- Offsets: 3
- Fill: No
Cutting¶
- Power: 75%
- Speed: 50 mm/min
- Offsets: 1
- Fill: No
Mylar ☆☆☆☆☆¶
- Machine: Laser Cutter
- Material: Mylar
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Power: 22%
- Speed: 1000 mm/min
- Offsets: 3
- Fill: No
Cutting¶
- Power: 60%
- Speed: 400 mm/min
- Offsets: 1
- Fill: No
Polyester film ★★★☆☆¶
- Machine: Laser Cutter
- Material: Polyester film
- Did it work?: Yes
- Layer configuration: 2 layers
Sealing¶
- Power: 25%
- Speed: 250 mm/min
- Offsets: 3
- Fill: No
Cutting¶
- Power: 30%
- Speed: 100 mm/min
- Offsets: 1
- Fill: No
3D printer sealing¶
For this process we can be more careful and accurate with the temperature, so we are able to use all of the material samples. Also it is important to say that we are not actually 3D printing, but using the hotend strategically to fuse the different layers. The most important part of this process is to stick the sheets to the printing bed, some high-temperature tapes work, also 3D printer glue is useful. Sometimes we need to trick the printer to print closer to the printing bed so the material fuses better. For most of the Creality printers, it is possible to use a piece of filament to "trick" the printer into printing. For Prusa printers it is possible to print without filament as an option.
Textile vinyl ☆☆☆☆☆¶
- Machine: 3D printer
- Material: Textile vinyl
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Hot end temperature: 150°-210°C
- Travel speed: 60 mm/min
- Z-offset (1st layer height): 0.1mm
- Number of passes: 1
- Wall number: 3
- Line width: .4mm
- Cooling fan: On
- Bed temperature: 65°C
Crystal PVC ☆☆☆☆☆¶
- Machine: 3D printer
- Material: Crystal PVC
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Hot end temperature: 150°-210°C
- Travel speed: 60 mm/min
- Z-offset (1st layer height): 0.1mm
- Number of passes: 1
- Wall number: 3
- Line width: .4mm
- Cooling fan: On
- Bed temperature: 65°C
Polyester film ☆☆☆☆☆¶
- Machine: 3D printer
- Material: Polyester film
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Hot end temperature: 150°-210°C
- Travel speed: 60 mm/min
- Z-offset (1st layer height): 0.1mm
- Number of passes: 1
- Wall number: 3
- Line width: .4mm
- Cooling fan: On
- Bed temperature: 65°C
Satin PVC ☆☆☆☆☆¶
- Machine: 3D printer
- Material: Satin PVC
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Hot end temperature: 150°-210°C
- Travel speed: 60 mm/min
- Z-offset (1st layer height): 0.1mm
- Number of passes: 1
- Wall number: 3
- Line width: .4mm
- Cooling fan: On
- Bed temperature: 65°C
LDPE ☆☆☆☆☆¶
- Machine: 3D printer
- Material: LDPE
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Hot end temperature: 150°-210°C
- Travel speed: 60 mm/min
- Z-offset (1st layer height): 0.1mm
- Number of passes: 1
- Wall number: 3
- Line width: .4mm
- Cooling fan: On
- Bed temperature: 65°C
Chip's bag ★★★★☆¶
- Machine: 3D printer
- Material: Polypropilene + aluminium film + Polyethylene
- Did it work?: YES
- Layer configuration: 2 layers
Sealing¶
- Hot end temperature: 150°-210°C
- Travel speed: 60 mm/min
- Z-offset (1st layer height): 0.1mm
- Number of passes: 1
- Wall number: 3
- Line width: .4mm
- Cooling fan: On
- Bed temperature: 65°C
Ziploc bag ☆☆☆☆☆¶
- Machine: 3D printer
- Material: Polyethylene film
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Hot end temperature: 150°-210°C
- Travel speed: 60 mm/min
- Z-offset (1st layer height): 0.1mm
- Number of passes: 1
- Wall number: 3
- Line width: .4mm
- Cooling fan: On
- Bed temperature: 65°C
RipStop ☆☆☆☆☆¶
- Machine: 3D printer
- Material: RipStop
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Hot end temperature: 150°-210°C
- Travel speed: 60 mm/min
- Z-offset (1st layer height): 0.1mm
- Number of passes: 1
- Wall number: 3
- Line width: .4mm
- Cooling fan: On
- Bed temperature: 65°C
Mylar ☆☆☆☆☆¶
- Machine: 3D printer
- Material: Mylar
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Hot end temperature: 150°-210°C
- Travel speed: 60 mm/min
- Z-offset (1st layer height): 0.1mm
- Number of passes: 1
- Wall number: 3
- Line width: .4mm
- Cooling fan: On
- Bed temperature: 65°C
Hot iron press¶
Using the hot iron press for textile vinyl we can fuse different layer of polymers. If we sandwich a sheet of, previously laser cut, kitchen waxed paper we can control which areas gete fused and which ones get to inflate. On the bottom part a tab was added for inflation.
Textile vinyl ★★★★★¶
- Machine: Hot iron press
- Material: Textile vinyl
- Did it work?: YES
- Layer configuration: 2 layers
Sealing¶
- Press temperature: 150°C
- Pressing time: 15s
- Observations: Brittle under pressure on sharp edges.
Crystal PVC ★★★★☆¶
- Machine: Hot iron press
- Material: Crystal PVC
- Did it work?: YES
- Layer configuration: 2 layers
Sealing¶
- Press temperature: 200°C
- Pressing time: 20s
- Observations: Special care
Polyester film ★★★★☆¶
- Machine: Hot iron press
- Material: Polyester
- Did it work?: YES
- Layer configuration: 2 layers
Sealing¶
- Press temperature: 150°C
- Pressing time: 5s
- Observations: Melts at high temperatures/times
Satin PVC ★★★★☆¶
- Machine: Hot iron press
- Material: Satin PVC
- Did it work?: YES
- Layer configuration: 2 layers
Sealing¶
- Press temperature: 200°C
- Pressing time: 15s
- Observations: Gets really soft with high temperature
LDPE ★★★★☆¶
- Machine: Hot iron press
- Material: LDPE
- Did it work?: YES
- Layer configuration: 2 layers
Sealing¶
- Press temperature: 100°C
- Pressing time: 60 mm/min
- Observations: Weak material, doesn't hold the pressure long.
Chip's bag ★☆☆☆☆¶
- Machine: Hot iron press
- Material: Chip's bag
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Press temperature: 200°C
- Pressing time: 10s
- Observations: Doesn't stick to itself
Ziploc bag ★★☆☆☆¶
- Machine: Hot iron press
- Material: Ziplock bag
- Did it work?: YES
- Layer configuration: 2 layers
Sealing¶
- Press temperature: 150°C
- Pressing time: 10s
- Observations: Hard to unstick from the press
RipStop ★★★☆☆¶
- Machine: Hot iron press
- Material: RipStop
- Did it work?: YES
- Layer configuration: 2 layers
Sealing¶
- Press temperature: 200°C
- Pressing time: 20s-25s
- Observations: Weak bonds
Mylar ☆☆☆☆☆¶
- Machine: Hot iron press
- Material: Mylar
- Did it work?: NO
- Layer configuration: 2 layers
Sealing¶
- Press temperature: 200°C
- Pressing time: 20s
- Observations: Doesn't stick to itself.
Bill of materials¶
| Component | Material | Specifications | Notes | Cost |
|---|---|---|---|---|
| Cover STRUCTURE | Corrugated cardboard | 5 mm thickness | Laser cut to create a rigid and lightweight structure | $5 USD per sheet. |
| Binding system | Paper binding pins | Standard two-hole punch spacing (~80 mm) | Allows pages to be added, removed, or rearranged | $2 USD per 10 pins |
| Interior pages | Paper sheets | Letter size, trimmed to 22 cm height | Ensures pages are protected within the cover | around $1.50 USD with color printing. |
| Inflatable sample pages | Plastic film / textile samples | Variable depending on experiment | Used for inflatable textile demonstrations | Around $30 USD for all the different sheets |
| Air pump compartment | Corrugated cardboard | Integrated into cover structure | Designed to hold a small manual hand pump | - |
| Manual air pump | Plastic hand pump | Hand pump for measuring blood pressure | Used to inflate the interactive pages | $17 USD for the whole kit |
| Adhesive | Paper glue | As required | Used for cover wrapping and assembly | $5 USD per liter |
| 3D printer use | 3D Printer | The university charges $1.50 MXN per minute (around $0.086 USD) | Around 3 minutes per test | $40.5 MXN - around $2.50 USD |
| Laser cuter use | laser cuter | The university charges $8 MXN per minute (around $0.45 USD) | ~2 minutes per test | $150 MXN - around $8.50 USD |
Final cost¶
The final cost of the booklet, budgeting the time of the machines use, materials, printing and assembly goes to:
- Somewhere around $72 USD if you were to recreate the booklet with similar costs than México and having access to the machines from a FabLab.
Evolution and maturation¶
The first proposal for this project was presented and reviewed, for which I had thorough feedback for both improvement and focalization on the topic.
First conceptual presentation
Midterm Presentation
Final Presentation
Story telling¶
This project began not with a product, but with a question: how can something as intangible as air become structure, insulation, or form?
Inflatable textiles exist all around us — in architecture, wearable systems, and soft robotics — yet their fabrication often remains hidden behind industrial processes. This project seeks to bring that knowledge into a more accessible space: the FabLab.
How to tell this story on the video?¶
The video opens in silence.
A series of slow, contemplative shots reveal a library space — shelves filled with books, knowledge accumulated over time. The camera moves gently, almost searching, until it pauses in front of a specific shelf. Among many volumes, one object stands out: a handmade booklet.
A hand reaches in and takes it.
Cut.
The scene shifts to a workspace. The booklet is placed on a table — a different environment, more active, more experimental. As it opens, the rhythm changes. Pages are flipped slowly, revealing fragments of research: materials, diagrams, processes, notes. The viewer is not just reading, but entering a process.
Each page suggests a stage of exploration — from early material tests to fabrication methods and system thinking. The book is no longer static; it becomes a map of experimentation.
Then, a small but significant gesture: a manual air pump is introduced.
It is connected to the booklet.
Air begins to flow.
The narrative shifts from observation to activation. Pages that once appeared flat begin to expand. Surfaces rise, structures take shape. The book quite literally comes to life — transforming from a container of information into a system that can be experienced physically.
Close-up shots emphasize this transformation: seams, textures, inflation, tension. The material responds, revealing both its possibilities and its limits. This moment bridges theory and practice — knowledge is no longer abstract, it becomes tangible.
As the inflatable samples activate, the voice-over reflects on the purpose of the project:
to explore, to test, to fail, to understand — and ultimately, to share.
The booklet is presented not as a finished object, but as a tool for others. A starting point. A system that can be replicated, expanded, and reinterpreted.
The motion slows down.
Air is released. The structures soften. The pages return to their original state.
The book is gently closed.
Cut.
We return to the library. The booklet is placed back on the shelf — now no longer just one among many, but something that carries process, experimentation, and potential.
The camera slowly moves away.
The space remains.
The final line says:
“because knowledge only matters when it is shared.”
The project concludes with a shift in perspective:
this is not about designing inflatable objects, but about designing the knowledge required to create them.
Through open documentation and distributed replication, the work invites others to continue the exploration — transforming a personal investigation into a collective, evolving process.
And the narration throughout the whole video talks about this realizations, and the importance of knowledge sharing and the possiblity of reproduction virtually everywhere:
Knowledge is scattered everywhere around us, stored in shelves, pages and fragments. But not all knowledge is easy to access, Some of it is technical, hidden in the processes, learned only through trial and error. Inflatable textiles are one of those cases, they exist across disciplines, but understanding how to make them is not always clear, the information exists, but it is often scattered, incomplete or difficult to reproduce. So the question became, How can this knowledge be gathered, structured and shared? What if a book was not only something you read, but something you could activate? Because knowledge is not static, it becomes alive when you use it, and even more when you share it. To understand this processes, you have to make them, to test materials, to explore them, to push them until they fail. Each variable matters: temperature, pressure, time, material. Small changes produce completely different behaviours, most attempts don't work the first time, and that's where the knowledge is because sealing is not just a step in the process, defines how the textile performs. A system that gathers materials, methods, and results, not only to document, but to make them understandable, extended through a platform where each process can be followed, replicated and adapted. Because this is not just about making objects, it's about enabling others to make their own. Because knowledge only matters when it can be shared.
You can check the final video below: