Multiple layers of hard silicone (Shore A 73) are printed with a seamless hexachiral structure on an inflated silicone balloon. When the layers are cured, the balloon is deflated, leaving a Minimum Energy Structure (MES) tube.
A 3D printer was built, capable of spray depositing silicone on to double curved (rotating) mandrels
I developed a technique for creating open cell soft silicone sponges. When coated in a conductive layer, these work well as soft pressure or stretch sensors.