Robo-top: The machines that could make your next t-shirt

Robots currently drive the assembly of automobiles, assist in complex surgeries, and manage logistics at major airports. However, hand a robot a needle and thread, and it is likely to fail. This technological limitation explains why the vast majority of the world’s apparel is still produced by human hands, frequently by low-wage laborers in Asia. While these workers utilize tools like sewing machines, fully automating the process has proven notoriously difficult.

“Sewing is a specific problem,” notes Cam Myers, founder and CEO of CreateMe, a robotics firm based in California. “The challenge lies in keeping two pieces of fabric aligned while they are in motion.”

CreateMe is bypassing the sewing hurdle entirely by opting for adhesion. “Instead of sewing, we glue the fabric pieces together,” Myers explains. “Once the adhesive is applied, you simply align a component over it and apply pressure.” CreateMe has engineered robots to execute this method and is currently manufacturing women’s underwear using this technique. The company plans to expand into t-shirt production in the coming months, with mass production anticipated for the following year.

For decades, roboticists have targeted the garment industry. If machines can successfully take over this labor, clothing production could return to Western nations, potentially significantly reducing the environmental impact of the fashion industry. However, this shift raises concerns for millions of textile workers who could lose their livelihoods. Currently, only a small fraction of clothing sold in the UK and the US is manufactured domestically.

Myers reports that he has clients interested in marketing products as “made in the US,” utilizing domestic materials like US-grown cotton. “Our adhesive-based process allows us to work with cotton, wool, and leather,” he says. He estimates that if automation helped just 10% of t-shirt manufacturing return to the US, it would trigger a massive shift in the industry.

Regarding durability, Myers insists that the thermoset adhesive used by CreateMe is robust enough to withstand ironing and washing machine temperatures without melting or causing garments to disintegrate. Furthermore, because these items lack traditional seams, they offer a streamlined fit and can be produced on molds that replicate the human body’s contours.

Despite these innovations, Myers acknowledges a significant hurdle: apparel is “high flex.” Simply producing basic white t-shirts will not suffice. Consumers demand endless variety in colors, designs, and fits. Consequently, robots are still far from replicating this full range of customization.

There is also ongoing debate regarding the best technological approach. Palaniswamy Rajan, chairman and CEO of Softwear Automation in Georgia, argues that “sewing is not going away.” He highlights that visible stitching remains a crucial design element in many fashion items, most notably jeans. Rajan states that his company will soon unveil its third-generation sewing robots, which he claims can produce t-shirts at a cost competitive with importing them to the US. However, he has declined to disclose specific technical details about the new technology.

Competition for dominance in the massive apparel market is fierce, leading multiple firms interviewed by the BBC to withhold information about their robotic processes. Meanwhile, textile workers are already facing instability, exacerbated by factory closures during the pandemic and recent disruptions to polyester supplies caused by the war in Iran. While automation advocates suggest workers should transition to higher-paying, less repetitive roles, handing over t-shirt production to robots will not achieve this outcome immediately.

One undeniable advantage of automating garment manufacturing is the potential to drastically lower the industry’s environmental footprint. Globally, 92 million tonnes of textile waste are generated annually, with massive quantities of unsold clothing being incinerated. Additionally, the sector consumes enormous amounts of water. “If we can bring manufacturing back onshore, we can produce on demand,” says Gerald Feichtinger at the Technical University...

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