Robo-top: The Machines That Could Weave Your Next T-Shirt

Robots have long mastered tasks ranging from automotive assembly and surgical procedures to handling airport cargo. However, equip most of these machines with a needle and thread, and they are likely to fail. Consequently, the vast majority of the world’s apparel is still manufactured by human hands, frequently relying on low-wage labor in Asia. While these workers utilize machinery like sewing machines, achieving full automation in this sector remains a formidable challenge.

“Sewing presents a specific problem,” explains Cam Myers, founder and CEO of California-based robotics firm CreateMe. “The difficulty lies in maintaining alignment between two pieces of fabric while in motion.”

CreateMe has opted for an alternative strategy: rather than stitching, they bond fabric pieces using adhesive. “Once the adhesive is applied, you simply align the next layer and apply pressure,” Myers notes. The company has already begun producing women’s underwear using this method and plans to launch t-shirt production in the coming months, with mass manufacturing expected to follow next year.

For decades, roboticists have viewed the garment industry as a prime target for automation. If machines successfully take over this work, clothing production could return to Western nations, potentially significantly reducing the environmental footprint of the textile industry. However, this shift could also displace millions of textile workers. Currently, only a small percentage of clothes sold in the UK and the US are manufactured domestically.

Myers reports that he has clients interested in marketing products as “made in the US,” particularly those using domestic materials like US-grown cotton. “Our adhesive-based process allows us to work with cotton, wool, leather, and more,” he says. He suggests that if automation enables just 10% of t-shirt manufacturing to relocate to the US, it would constitute a major shift in the industry.

Addressing durability concerns, Myers insists that the thermoset adhesive used by CreateMe is resistant to the temperatures of washing machines and irons, ensuring garments do not fall apart. Furthermore, because these clothes are seam-free, they offer a streamlined fit and can be produced on molds that replicate the human body’s contours.

Despite these advances, Myers acknowledges that the apparel sector is inherently “high flex.” Producing only basic white t-shirts is insufficient; consumers demand a wide variety of designs, colors, and styles. Current clothing robots are far from replicating this diversity.

There is also ongoing debate regarding the best approach to automation. “We do not believe sewing is disappearing,” states Palaniswamy Rajan, chairman and CEO of Georgia-based Softwear Automation. He highlights that visible stitching remains a crucial design element in many fashion items, most notably jeans. Rajan claims his company is preparing to unveil its third-generation sewing robots, which he asserts will produce t-shirts at a cost comparable to importing them to the US. However, he has refused to disclose technical details.

Competition for dominance in the massive apparel market has led to secrecy among industry players. Multiple firms interviewed by the BBC declined to share specifics about their robotic technologies.

Meanwhile, textile workers are already facing significant pressure, having endured factory closures during the pandemic and recent supply chain disruptions caused by the war in Iran, which has impacted polyester availability. While automation advocates argue that workers should transition to higher-paying, less repetitive roles, simply replacing humans with robots will not achieve this outcome instantly.

One significant advantage of automating garment production is the potential to drastically lower the industry’s environmental impact. Globally, 92 million tonnes of textile waste are generated annually, with large quantities of unsold clothing being incinerated. Additionally, the sector consumes enormous amounts of water.

“If we can bring manufacturing back to our own shores, we can produce on demand,” says Gerald Feichtinger of the Technical University...

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