ExoFabric: A Re-moldable Textile System for Creating Customizable Soft Goods and Wearable Applications

Fabric has been a fundamental part of human life for thousands of years, providing comfort, protection, and aesthetic expression. While modern advancements have enhanced fabric's functionality, it remains static and unchangeable, failing to adapt to our evolving body shapes and preferences. This lack of adaptability can lead to unsustainable practices, as consumers often buy more items to meet their changing needs. In this paper, we propose ExoFabric, a re-moldable fabric system for customized soft goods applications. We created ExoFabric by embedding thermoplastic threads into fabric through computerized embroidery to allow for tunability between rigid plastic and conformable fabric. We defined a library of design primitives to enable geometric formability, stiffness, and stretchability by identifying suitable fabrics, threads, embroidery parameters, and machine limitations. To facilitate practical applications, we demonstrated practical methods for linking parameters to application requirements, showcasing form-fitting wearables, structural support, and shape-changeable furniture for repeatable or one-time customization.