In recent years, 3D printing has moved beyond the boundaries of industry and product design to enter the world of fashion, giving designers unprecedented tools to create innovative garments and accessories. Thanks to technologies such as FDM, Multi Jet Fusion and resin printing, it is now possible to produce printed fabrics, flexible structures, decorative details and bespoke components that combine aesthetics and functionality. The combination of geometric freedom, personalisation and material choice is transforming how we conceive garment design and production. This article explores the main technologies, materials and real-world case studies to understand how additive manufacturing is redefining the concept of contemporary fashion.
Fused deposition modeling (FDM) is the most widespread and accessible 3D printing technology, known for its affordability and versatility. In the fashion context, FDM offers the opportunity to prototype and produce both rigid and flexible wearable elements using thermoplastic filaments. FDM printers extrude a molten filament layer by layer, gradually building the object. Common materials (PLA, ABS, PETG) are rigid, but there are also flexible filaments such as TPU (thermoplastic polyurethane), which open the door to soft and deformable printed garments and accessories.
With high-quality flexible filaments, it is possible to print 3D "fabrics" or comfortable wearable parts. For example, designer Danit Peleg created an entire fashion collection using highly flexible Filaflex TPU filament and small domestic FDM printers. Her 2015 graduation project consisted of garments that were printed rather than sewn: after nine months of experimentation, Peleg found in Filaflex a highly flexible and durable plastic with which she printed a jacket (taking around 2,000 hours of printing on desktop machines to produce the garment). This example illustrates both the possibilities (creating customised clothing without traditional textiles) and the challenges (long printing times, the need to split the model into parts). FDM also enables the production of customised rigid accessories and decorative parts (e.g., buckles, armour components for cosplay, large jewellery pieces) using materials such as PLA/ABS, although these are more suited to non-flexible components.
The reference material for garments printed with FDM is TPU with Shore hardness around 85–95A (similar to rubber). TPU combines softness, elasticity and durability: ideal for components that must flex while withstanding mechanical stresses. It offers high elasticity and low modulus, returning to its original shape after deformation. This makes it perfect for parts requiring comfort and adaptability, such as elastic inserts, wearable sleeves, belts or ergonomic soles. Furthermore, TPU has properties beneficial for wearables: it absorbs shocks and dampens vibrations, protecting against impacts and dynamic stress, and is highly tear-resistant. A major advantage for outdoor garments and accessories is its weather resistance: 3D-printed TPU retains its integrity and properties outdoors thanks to excellent UV and hydrolysis (moisture) resistance. This means TPU parts can be exposed to sunlight without rapidly degrading or hardening. Sportswear designers already exploit these qualities to produce elastic bands, shoe components and ergonomic supports that must withstand constant bending.
However, using flexible filaments in FDM comes with technical limitations. Printing TPU requires well-calibrated machines. It is often necessary to reduce speed and adopt specific settings to achieve reliable prints. Greater wall thickness reduces flexibility: in particularly thick sections, a TPU part will be more rigid, so designers must keep sections thin or incorporate holes/lattices to preserve softness. Another limitation of FDM is resolution and finish: parts show visible layer lines and less fine detail compared to other technologies, which can affect the aesthetics of a garment. Finishing processes are often employed to improve skin comfort and appearance.
HP's Multi Jet Fusion (MJF) technology is one of the most advanced additive methods for producing high-quality plastic parts. In fashion, MJF opens up unique possibilities: complex lattice structures, meshes and mobile interconnections can be produced in a single piece—impossible to achieve with techniques requiring supports.
In addition to flexible meshes for printed fabrics, MJF excels in producing fashion components with high detail and robustness, such as bespoke jewellery and accessories. The process’s precision (typically 80 μm layers) enables intricate textures and industrial-quality finishes. Compared with FDM, MJF parts have tighter tolerances and no visible layer lines on vertical surfaces. Furthermore, the lack of supports allows total geometric freedom: intricate embellishments, raised textures on garments, buckles with internal moving mechanisms, etc., can be printed without concern for support removal. Another advantage for fashion is small-batch production: MJF enables dozens of elements to be printed in the same build (filling the build box with multiple parts). This makes it ideal for producing limited-run collections of bespoke nylon accessories or garment components with end-use quality, not just prototypes. For instance, an entire set of panels for assembly into a modular dress, or numerous unique buttons or jewellery pieces for a custom fashion line, can be printed at once.
Resin 3D printing (SLA, DLP, LCD technologies) uses liquid photopolymers cured layer by layer by a UV light source. This category is renowned for the extremely high resolution and precision achievable: very fine details, smooth, uniform surfaces—ideal for objects with complex, minute geometries. In fashion, resin printing is particularly suited to decorative accessories, ornamental elements, high-detail design prototypes, and small components requiring flawless finishes (e.g., artistic buttons, jewellery parts, 3D applications on garments).
The primary strength of resin printing lies in its aesthetic quality. Objects emerge from the printer with smooth surfaces and crisp details, often requiring minimal finishing (aside from support contact points). This is essential for visible components on high-end garments, where appearance must be impeccable. For example, 3D lace decorations, architectural elements applied to a dress (as seen in some haute couture creations), buckles or designer eyewear components can be printed in resin with a definition almost indistinguishable from injection-moulded parts. Another advantage is the range of specialised materials: transparent resins for visual effects, elastic and rubber-like resins for flexible parts, and high-heat-resistant resins for technical applications. This versatility allows designers to select the right resin for the intended use.
Resin printing also enables micro-details and ultra-fine textures to be created directly on the piece. Imagine a raised lace-like pattern or intricate motifs on a surface: SLA can reproduce sub-millimetre patterns, adding a visual complexity to printed garments impossible with FDM. Some designers have experimented with resin printing to produce 3D applications on traditional fabric (e.g., printed elements later glued or sewn onto the garment) or to create rigid “sculpture” garments. While the output is rigid, the spectacular effect comes from the precision of the organic forms achieved.
One limitation of this technology is the fragility of standard resins: conventional resins tend to be rigid but brittle, with low elongation. A decorative button printed in resin may break if struck or bent, whereas the same piece in MJF nylon would endure. For this reason, when load-bearing or stress-prone parts are needed, MJF or FDM is preferable. Moreover, photopolymer resins have poor long-term UV resistance: UV light degrades the polymer structure, causing yellowing and brittleness. This makes them less suitable for everyday outdoor garments unless protective treatments are applied or UV-stable resins are used. Safety and biocompatibility are also important: resins are chemically active until fully cured, so thorough post-processing is required. Wearing an incompletely cured resin piece against the skin may cause irritation or allergies. Medical-grade certified resins exist and are recommended for direct skin contact. It is generally advisable to include a textile lining between the skin and large resin components. Finally, resin printing requires supports during production, meaning complex parts must be carefully oriented and cleaned of supports. Contact points may need sanding and touch-ups (some providers, such as Weerg, offer “basic” or “professional” finishing services for resins, with the latter eliminating support marks and evening out surfaces). This manual step should be factored into the production of multiple parts to be assembled onto a garment.
To put these technologies into context, here are some real examples of 3D fashion achieved with FDM, MJF or resin:
Running shoes with 3D-printed lattice midsoles: In sports footwear, brands like Adidas and New Balance have introduced shoes with 3D-printed lattice midsoles. The idea is to exploit an elastic lattice structure to improve flexibility and shock absorption. The 3D midsole provides customised cushioning and geometries impossible to produce otherwise.
Custom fashion accessories: Additive manufacturing has found fertile ground in accessories such as eyewear and jewellery. Sunglasses printed in PA12 nylon via MJF offer lightweight, robust frames custom-fitted to the wearer’s face. Complex details can be integrated into the arms or ergonomic textures applied. Similarly, many jewellery designers use resin to create elaborate shapes for metal casting, or directly produce brightly coloured technical-resin plastic jewellery. The ability to achieve bespoke geometries and mass customisation is a growing trend: customers can specify shape and size, and 3D printing makes each unique piece manufacturable.
Armour and cosplay costumes: Beyond high fashion, a practical application of 3D printing is in creating armour, exoskeletal props and costumes for entertainment. In film/theatre and cosplay, printing custom-fit armour parts is now common. FDM is used for large, rigid parts—such as Iron Man armour, helmets and shields—later finished and painted. MJF comes into play for parts requiring greater strength and detail: e.g., joints for exoskeletons, articulated gloves or elaborate decorations. TPU is also used for soft segments: gaskets, body-contact parts for comfort, and even flexible chainmail worn beneath armour (instead of real metal mail). These printed armours highlight practical benefits: reduced weight compared to metal, anatomical customisation, and the ability to integrate decorative forms achievable only with 3D printing.
3D printing applied to fashion is no longer a futuristic experiment but a tangible reality opening up new creative and production perspectives. Whether it’s rapid FDM prototyping, functional MJF components or ultra-precise resin decorative details, each technology offers unique strengths and limitations to be understood. The winning approach is not to choose a single path but to combine materials and processes according to the project’s aesthetic, mechanical and functional needs. In this way, 3D printing becomes a true ally for designers, blending digital craftsmanship with creative freedom, paving the way for garments and accessories that, just a few years ago, were simply unimaginable.