Flat-to-shape objects fabricated with a CNC sewing machine

How can we harness the unique capabilities of the overlooked CNC sewing machine, traditionally only used to make soft blankets, and expand its fabrication possibilities?

Deployable objects allow quick activation and compact storage but often require intricate assembly processes. We establish a novel rapid, scalable method to fabricate functional objects using a large computer-controlled quilting machine (11 ft / 3.4 m wide). Rigid materials like plywood or acrylic are sandwiched between fabric layers and secured through sewing, forming soft hinges. These hinges allow smooth transitions into three-dimensional forms with minimal post-processing.

Full paper

I first authored this paper in collaboration with Dr. Lea Albaugh, Dr. Jim McCann and Dr. Scott Hudson.

Accepted to ACM Human Factors in Computing Systems, CHI 2025. [Presenting in Yokohama in April!]

Flat-to-shape steps of the side table

Method Overview

Longarm Quilting Machine. Fabric is tensioned over the rollers.

Leveraging the machine’s strengths

Modern CNC quilting machines, offer precision, reliability, and scale. However, their potential remains largely untapped beyond flat, fabric-based products like quilts.

We take advantage of the machine’s unique features to craft unique, surprising, fully functional objects.

Computer-controlled sewing and panel insertion for the backpack design (10x speed).

Human-machine co-creation

Establishing an incremental fabrication process with alternating passes of sewing pockets and placing inserts.

Designed Objects

1. Lamp

Made up of four panel types for localized functions to achieve dynamic functionality: plain acrylic at the base, cardstock-laminated panels in the inner ring, LED-integrated "active" panels in the upright section, and open spaces at the top for a graceful fabric drape as the lampshade.

2. Backpack

Inspired by packaging design, a tendon cord system transforms the bag from flat to 3D and doubles as the straps. Made of 3/16" plywood inserts. Gusset panels remain flexible with Velcro for selective attachment and locking.

3. Side Table

Transforming with a simple tug secured with a spring cord lock while in use. The cord acts on short rectangular struts, which meet in the center under the tabletop when fully deployed, stopping further movement.

4. Lounge Chair

A large (60" by 56" when flat) chair designed to support an adult’s weight.

The insert panels, made from 1/2" plywood cut on a CNC router, are designed to meet face-to-face when deployed. Neodymium magnets, glued into milled pockets, allow the chair to "snap" into place, aligning the panels, while the fabric and panels carry the primary loads.

Design Process

Sewing Possibilities

A research-through-design process to play with different sewing and gathering methods and studying their effects.

Geometry and Method Tuning

Prototyping possible forms.

Technical Process

Chair fabrication process where a table and weights are used to build objects larger than the bed size.

Left: Original machine set up. Right: Our modifications to expand fabrication scope.

Scaling up

We adapt the machine (11 ft × 25 in sewing area) for large scale rigid panel fabrication by replacing the typical fabric rolling method with a height-adjustable table. A weighted rod threaded through the fabric edge maintains tension and alignment during stitching.

Path and Panel Sequence AlgorithmIn the paper, we formalize a repeatable design space to share our discoveries. Reach out for more information!

Putting the CNC Sewing machine together!

Mid-project we needed to move the machine (~13’ by 5’) from it’s original home in Robotics to the HCI lab across campus.

Taking the machine apart and putting it back together was an incredible opportunity to learn about its workings and nuances of operating it!