Here’s a piece by Aaron Trocola about his work featured in the 3D Fashion gallery and runway show at NY 3D Print Show a few weeks ago! ThreeForm’s Articulated Gymnast Ensembles, at MAKE:
For a live performance at the 3D PrintShow fashion show, ThreeForm Fashion designed five custom outfits for the Purple Knights gymnastic team. The gymnasts were scanned with a high quality phase-based structured-light system, and the designs were created around that data to ensure a perfect fit.
An articulated ball-joint system was designed so that if an extreme angle pushes the ball out of the socket, the cord pulls it back into place. This prevents the structure from restricting the performers movement, but still prevents failure of the joint when force or angle exceeds specification.
…The sections are joined with elastic straps. 3D Printed parts can easily be made flexible, but significant elasticity is a property that is still largely elusive. The lengths of each strap were calculated by measuring the length of a spline on the surface of the scan data, shortened by 20 percent to pre-tension the strap, with one inch added at each end for the fold of material used for fastening. The straps were joined with a combination of 3M Seamstick tape (a double sided adhesive used for assembling racing sails), and “Liquid stitch” which re-enforced the bond after setting. This allowed the garment to be assembled quickly and reliably, but still manually disassembled for adjustment or repair without sewing.
…3D printed clothing is good for more than just wearable art and sculpture. With proper design and construction, it can accomplish amazing feats of flexibility, durability, and reliability. As materials and processes improve, expect these capabilities to be even more accessible to makers everywhere.