Robo-top: The Machines Behind Your Next T-Shirt

While robots currently dominate industries ranging from automotive assembly and surgical procedures to airport logistics, equipping them with a needle and thread remains a significant hurdle. Consequently, the vast majority of the world’s apparel is still crafted by human hands, frequently employing low-wage laborers in Asian nations. Although these workers utilize machinery like sewing machines, achieving full automation for such intricate tasks has proven difficult.

“Sewing presents a specific challenge,” explains Cam Myers, founder and CEO of CreateMe, a robotics firm based in California. “You must maintain alignment between two pieces of fabric while they are in motion.” To bypass this issue, CreateMe has adopted an alternative strategy: instead of stitching, they bond fabric pieces using adhesive. According to Myers, “Once the glue is applied, you simply position another layer on top and press.”

The company has already deployed robots to manufacture women’s underwear using this method and plans to expand into t-shirt production within the next few months, with mass production slated for the following year. For decades, roboticists have targeted the garment industry, envisioning a future where machines could reclaim clothing production in Western nations, potentially reducing the environmental impact of fashion. However, this shift raises concerns about job security for millions of textile workers. Currently, only a small fraction of clothing sold in the UK and the US is domestically produced.

Myers notes that he has clients interested in marketing garments as “Made in the US,” utilizing local materials like cotton. He highlights the versatility of CreateMe’s adhesive technique, stating, “We can work with cotton, wool, leather, and more.” He estimates that if automation enabled just 10% of t-shirt manufacturing to return to the US, it would trigger a massive industry transformation.

Regarding durability, Myers insists that the thermoset adhesive used is resistant to heat, meaning standard washing and ironing temperatures will not cause the garments to disintegrate. He adds that because these items lack traditional seams, they are more streamlined and can be produced using molds that conform to the human body’s contours.

However, Myers acknowledges a major limitation: apparel is inherently “high flex.” He admits that focusing solely on basic white t-shirts limits market success, as consumers demand a wide variety of colors, designs, and fits. Current clothing robots are far from replicating this diversity.

There is also ongoing debate regarding the best technological approach. Palaniswanyi Rajan, chairman and CEO of Georgia-based Softwear Automation, argues against the idea that sewing is obsolete. “We do not believe sewing will disappear,” he says, pointing out that visible stitching is essential for the aesthetic of many fashion items, particularly jeans. Softwear Automation is preparing to unveil its third-generation sewing robots, which Rajan claims can produce t-shirts at a cost comparable to importing them to the US. However, he has refused to disclose technical details.

Competition in the lucrative apparel market has led to a culture of secrecy among manufacturers, with multiple companies declining to share specifics about their robotic processes with the BBC. Meanwhile, the workforce faces existing pressures, including factory shutdowns during the pandemic and recent disruptions to polyester supplies due to the war in Iran. While industry advocates suggest workers should transition to higher-paying, less repetitive roles, the shift to robotic t-shirt production will not happen instantaneously.

One significant advantage of automation, however, is its potential to mitigate the environmental toll of the industry. Globally, the sector generates 92 million tonnes of textile waste annually, with massive quantities of unsold clothing being burned. Additionally, apparel production is water-intensive. “Reshoring manufacturing allows for on-demand production,” says Gerald Feichtinger at the Technical University.

Source: BBC News Generated at: 2026-05-18 23:04:14 UTC