Project Statement

This project investigates biomimicry-inspired honeycomb padding systems for performance apparel and protective gear, with a focus on modular textile integration and lightweight impact absorption. Using TPU printed hexagon structures bonded to mesh and sewn into muslin the system demonstrates how additive manufacturing can create protective geometries that function as part of the garment rather than an external add-on. The design draws from natural hexagonal honeycomb patterns structures optimized for strength and material efficiency to create padding that distributes impact forces while maintaining breathability and flexibility. By integrating the structure directly into textiles, the system aims to improve wearability, reduce bulk, and enable customizable protection for applications such as mountain biking and high-mobility athletics. This project is not just about creating padding; it explores the intersection of material science, industrial design, and biomimicry to reimagine how protective systems can be lightweight, adaptable, and textile-friendly.

Why

I pursued this project because traditional padding systems in sports and protective apparel often force trade-offs between protection and mobility. Foam-based solutions can be bulky, heat-retaining, and prone to permanent compression over time, reducing long-term performance. Rigid inserts offer impact resistance but limit flexibility and comfort. These limitations highlight an opportunity to rethink protective design through structural innovation rather than material thickness. Biomimicry provides a powerful design framework because natural systems solve complex engineering problems with elegant efficiency. Honeycomb geometries in nature achieve high strength-to-weight ratios and distribute forces effectively using minimal material. Translating this strategy into TPU hexagon structures allows for controlled deformation during impact absorbing energy where it matters while remaining lightweight and breathable. Additionally, integrating the hexagon into textiles addresses a persistent issue in protective apparel: compatibility with garments.This project explores how design and material innovation can meet that demand.

Precedents

Conceptual, technical, and visual

Conceptual Precedent

Name: Armadillo

Technical Precedent

Name: Biker Armor

Visual Precedent

Name: Scale armor

Sketches

Sketches

Iteration I

the first iteration of a glove that would be attached to a jacket

Iteration II

inside view

Infill: 10%

Wall Thickness: 5mm and 10mm

Notes: More compact but still bendable, best iteration

Iteration I - TPU Printing

Iteration II - TPU Printing

Infill: 10%

Wall Thickness: 5mm and 10mm

Notes: Failed as it stuck to the bed of the printer

Iteration I - TPU Printing With Mesh Layer

Infill: 10%

Wall Thickness: 8mm and 16mm

Notes: Best combination for impact absorption and structure

Iteration II - TPU Printing With Mesh Layer

Infill: 10%

Wall Thickness: 3mm and 6mm

Notes: Thin but more bendable

Iteration III - TPU Print With Mesh Layer, Sewn To Fabric

Infill:15%

Wall Thickness: 3mm at smallest point and 6mm at thickest

Notes: Height too tall, need to decrease infill

1) find actual metrics to test them

2) make specific padding for certain body parts

3) sow it into a jacket

Next Steps