Morphological Reinforcement in Monomaterial Garments Through Origami-Based Textile Surfaces

This study investigates topology-driven reinforcement strategies in monomaterial textile garments through the integration of origami-based metastructures. We hypothesize that fold geometry, rather than material addition, can provide localized mechanical reinforcement while preserving recyclability within a circular design framework. A bio-based textile system was developed using a Lyocell substrate coated with a sawdust-derived biocomposite applied via a knife-over-roller technique. Two origami tessellations—Miura-ori and Herringbone—were parametrically implemented and assigned to garment zones based on biomechanical stress mapping. Experimental evaluation demonstrated that origami-structured zones improved abrasion resistance by up to 6.1% relative to the flat coated substrate (up to 40% relative to uncoated Lyocell), compression resistance by up to 39%, and water vapour transmission by up to 38.8% compared to the flat coated substrate, while maintaining geometric retention above 91% after cyclic loading. These results confirm that morphological structuring redistributes mechanical stress without introducing heterogeneous materials; geometric stability was demonstrated over 10 flexion cycles and should not be interpreted as evidence of long-term in-use durability. The findings establish fold topology as a functional design variable in textile engineering and demonstrate its potential to advance monomaterial systems aligned with circular economy principles.