Hybrid Layers

From Structure to Softness
| 2023

3D printing isn’t just for rigid objects—when fused directly onto fabric, it transforms into something entirely new. By printing TPU onto high-texture, high-weave textiles, this process creates a flexible, durable bond without the need for adhesives. The result is a seamless integration of structure and softness, pushing the limits of what fabric can be.

Developed through a series of experiments, the technique refines material selection and print parameters to achieve the strongest possible adhesion while preserving the fabric’s flexibility. This direct-on-fabric printing method opens new possibilities for hybrid textiles, wearables, and functional soft goods, bridging digital fabrication with traditional materials in ways that feel both innovative and scalable.

By embedding structure into fabric itself, this process challenges conventional textile production, offering new ways to think about adaptable materials, responsive surfaces, and customizable manufacturing. From wearable technology and modular accessories to medical applications and interior surfaces, the ability to precisely print onto textiles opens up possibilities beyond fashion—turning soft materials into functional, high-performance systems.

This project enhances the
well-being of a serval at the Roger Williams Park Zoo by providing interactive and stimulating enrichment. Designed to engage the serval’s natural instincts, it encourages exploration, problem-solving, and physical activity.

In captivity, the absence of hunting can lead to a decline in motor skills and reflexes. This tethering toy helps counteract that by challenging the serval’s agility, balance, and precision through dynamic, unpredictable movement.

This enrichment tool was constructed using a combination of metal and 3D-printed components to ensure durability and modularity.
The core structure consists of an aluminum rod with a threaded top, allowing for easy attachment of interchangeable enrichment elements. The base is assembled from a series of 3D-printed components, designed in Rhino and printed at full scale over several days.

Before final production, a small-scale prototype was printed and demonstrated to the zookeeper for approval, ensuring the design aligned with the serval’s enrichment needs. The modular design enables zookeepers to customize the enrichment experience by swapping attachments, promoting varied and sustained engagement.

Construction & Fabrication