This Master’s thesis report contains research about applying textile to the outer housing surface of products. The research was conducted in collaboration with Signify, a company that creates smart home luminaires for the brand Philips Hue. The goal of the project was to create design guidelines which the designers of Signify can use to create textile building blocks for their luminaires.

The project explores suitable textiles, shaping possibilities and fastening methods. The most relevant insights are summarized on “Design Guidelines” pages. A “Design Decision Tree” (DDT) was created to navigate through the Design Guidelines. The DDT can be used by designers who have a housing shape in mind to learn about the relevant insights for applying textile to their specific surface.

Suitable textiles for surface application are researched. It was determined that knitted and woven fabrics are suitable for surface coverage. Non-woven fabrics are not because of their undesired appearance and minimal required thickness which impedes mechanical fastening.

Shaping possibilities were explored for covering surfaces with flat sheets of fabric as well as covering continuous surfaces with tubular textiles. Depending on the properties of a surface, certain fabrics and fastening methods can or cannot be used. The design limitations per surface category are summarized in the Design Guidelines.

Most current textile housings are fabricated by gluing or welding the textiles to the outer surface and inner edges of the part. This method obstructs easy disassembly. An alternative method was created. This “clamping” fastening method is considered more sustainable because it allows the housing to be disassembled with ease and therefor repaired or recycled more efficiently. A clear use cue was added to the inside of the clamping mechanism to inform the user about its disassembly potential.

In addition to the gluing and clamping method, creating a separate sleeve was explored. To fabricate such a sleeve, 3D-knitting can be used. Literature research was conducted to explore the possibilities of knitting three-dimensional shapes on flatbed and circular knitting machines to cover product housings.

A novel product concept for Philips Hue was created. A prototype of the concept was made to demonstrate textile building blocks in the context of a luminaire. This product concept is called the “Rotation Lamp” and it is used as a tool throughout the report for experimenting and validating. The Rotation Lamp is inviting to touch because of its textile parts. It is intended to be kept close to the user and to enhance their well-being by providing them with a lamp that suits their need for ambience and functional light. Three sets of textile housings were created for the prototype to observe the different product aesthetics that these could create.