03.

Padded Workwear Project

Integration of 3D-printed components within apparel construction

©2024/2025

My idea for the Padded Workwear Project began with an interest in exploring how 3D printed parts could be integrated into cut and sewn garments. Using a foaming TPU filament I designed pads that

could slide into pockets on the knee and calf. This project was completed using 15oz selevege denim and traditional single stitch method of assembling the garment. The pants also use

copper buttons and rivets and a traditional button fly similar to the construction style of jeans at the turn of the 19th century.

Padded Workwear Project Modeled

Details

CLO 3D Render

CLO3D Animation

Button Fly

Foam Pads

The 3D printed foam pads are held in place not only by their rough texture against the denim, but also through a tab that was implemented into their design. This tab (Shown on the right) folds back and slides through the hole made in the “Pad pockets”.

Copper Rivets

Copper rivets provide strength in an area that will get stressed by pulling the pads in and out over a long period of time

Tab Slot Edges

The edges of the tab slot are hand sewn to prevent fraying, and use a thread color similar to that of the raw denim.

Pad Detail

Pad Ideation + Sketches

While experimenting with different ways to print with this unique foam TPU filament, I discovered that if printed at a certain thickness, the result was very similar to fabric. This is very helpful when creating leg pads that need to provide

cushion for the wearer, but also move easily in every direction.
Two vastly different forms work together to create these 3D printed front and back leg pads. The extruded forms provide the impact resistance while the 0.08

inch thick plane connecting them allows for movement like a fabric. With the .125 inch gap between each module, the pads are able to bend freely, morphing to any movement the wearer makes.

Before creating this project I had to learn how to construct a traditional pair of jeans. I created the pattern in CLO3D and itterated over the course of several months. After sewing a dozen pairs of jeans on cheap denim, I had achieved the shape and fit that I wanted.

This served as a starting point for the additions such as pad pockets, and layering seen the final result.
The design of the pads also went through a considerable amount of itteration. The stack of pads (Shown on the right) took an estimated 375+ hours of total

printing time to arrive at the final pad design. The idea started in grasshopper, using parametric design to morph twisted boxes into the shape of the pattern. However, this design was very restrictive of movement.

Initial Pad Ideation