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When Kendra’s design stepped onto the runway at the Academy of Art University in San Francisco, it wasn’t just a senior thesis, it was a challenge to the fashion industry to rethink how materials, technology, and sustainability can collide. Crafted using Balena and Recreus, Balena.FilaFlex, a compostable, bio-based filament made for wearable innovation, the dress transformed seafoam into sculpture, fashion into function, and plastic into possibility.
Kendra’s piece wasn’t just visually striking, it was built layer by layer with intention. As the only student in her cohort experimenting with 3D printing, she saw an opportunity to push beyond conventional textiles and explore what circular design could really look like. Inspired by ocean elements and driven by a desire to reduce fashion’s environmental footprint, she turned to Balena.Filaflex, Balena’s and Recrues, flexible, durable, and fully compostable material engineered for additive manufacturing. The result?
A dress that didn’t just move with the body, it moved the conversation forward.
“When the filament became available, I bought it that day. The prototyping commenced immediately.”
The Dress That Made Everyone Stop and Stare
Kendra envisioned a garment that would both command attention and start a conversation and what better way to do that than with a fully 3D-printed dress?
“Why not?” she laughs. “You have to find ways to stand out.”
Drawing inspiration from seafoam and beach rocks, Kendra constructed the piece by draping in 3D, building it directly on a dress form. She used gyroid infill to echo organic structures and tested the design on multiple wearers to ensure it could move, flex, and hold its shape. While avant-garde by nature, the final dress proved both resilient and runway-ready.
“People couldn’t stop touching it,and that’s exactly what I hoped for.”
Prototyping in Motion: Designing with Balena.Filaflex
Behind the elegance of the final garment was a process defined by trial, precision, and a deep understanding of material behavior. Kendra approached the design as both artist and engineer, translating oceanic inspiration into a fully wearable structure.
She began by dropping a reference image into Illustrator to create the base pattern, then moved into Rhino to build the 3D geometry and introduce height variations to the pieces. By removing the top and bottom layers during slicing, she achieved a sense of transparency and lightness. The use of gyroid infill gave the structure an organic quality, while multiple size and height variations allowed her to find the perfect balance between flexibility and form. Nothing in the piece was thicker than 15 mm,ensuring comfort without compromising strength.
“I tested the garment on at least three people to make sure, first, that a human could actually get into the dress, and second, that it would hold together. I can confidently say this filament is durable.”
Between two runway shows, the dress held its shape impressively, requiring only a minor touch-up caused by a thinner printed section. That repair, Kendra notes, was quick and expected. “I was prepared for it, and it was easy to fix.”
While the dress was designed for impact rather than everyday wear, it still offered surprising versatility. “I believe the model could have sat down in it,” she says, “but she didn’t wear it much longer than the runway. I’d love to see how the dress performs in a more demanding setting.”
What mattered most to Kendra was how the piece moved, how it danced with light, flexed with the body, and caught attention without asking for it. “I wanted something that would make people stop, look longer, and spark conversation, because they had never seen anything like it before.”
Available to purchase > Balena.Filaflex
Printing with Purpose: Why the Material Matters
As with any first-time material, Kendra admits she had some initial hesitation.
“Deep sigh… What am I getting myself into?”
But once she got hands-on Balena.Filaflex, the experience reshaped her expectations. Unlike other flexible filaments,particularly petroleum-based TPUs,Balena’s formulation allowed for lower-temperature printing and reduced strain on the printer itself.
“You can print at a lower temperature, which in my opinion leads to a better outcome for your printer. It’s less likely to melt your hot end, unlike what happened to me with TPU.”
Beyond functionality, what stood out most was how the material felt. Soft, flexible, and natural to the touch, Balena.Filaflex brought a completely new sensory dimension to wearable printing. For Kendra, that opened up the possibility of building garments that were sculptural yet human, designed not just to be seen, but experienced.
“Wearable art and 3D printing almost go hand in hand if you ask me. The way this filament feels and reacts is unlike any other flexible filament out there. It really pushed the boundaries of what can be made with a 3D printer.”
Before adding, “I mean, did you see my dress? She is cute!”
Advice for Designers Curious About 3D Printing
Kendra’s advice? Be patient, be curious, and be ready to experiment.
“Dial in your settings, take your time, and invest in a good filament dryer. Once you get the hang of it, the possibilities really open up.”
Instagram @KaeRaePrints and @KaeRaeProductions.
