Laurin Schaffner & Benjamin Relly present foldable surgical tool
Designers Laurin Schaffner and Benjamin Relly, in collaboration with ETH Zurich spin-off Hylomorph and Zurich University of the Arts (ZHdK) unveil 3FOLD, a foldable, origami-inspired surgical tool that helps doctors safely apply protective pouches around pacemakers and neurostimulators. The device, produced in tear-proof Tyvek, a synthetic, nonwoven material made from high-density polyethylene fibers, unfolds in seconds during surgery, reducing application time from five minutes to just three seconds while minimizing the risk of contamination or damage.
final prototype series in a flat state
3FOLD draws from origami, kirigami, and auxetic structures
Every year, more than two million implants are placed worldwide. While these devices are life-saving, complications often arise from scarring and infection around the implant. To counter this, Hylomorph created Hylomate, a biocompatible pouch that wraps the implant to safeguard the body. However, its soft and slippery surface made it difficult to handle with conventional surgical tools. Standard tweezers could tear the pouch, while direct hand contact risked contamination, calling for a new solution.
Laurin Schaffner and Benjamin Relly shaped 3FOLD precisely for this delicate environment. Shipped flat, the tool folds into a stable structure in a single motion, enabling the pouch to be positioned quickly and without direct touch. The design process drew inspiration from origami, kirigami, and auxetic structures, resulting in a simple fold that unlocks complex functionality. More than 500 prototypes were tested and refined with clinical staff before the final iteration was integrated directly into the sterile packaging of Hylomate.
The project also marked a shift in design research methods during the COVID-19 pandemic. With in-person testing impossible, the team developed remote usability protocols. Prototypes were shipped to clinicians, surgeries simulated via video calls, and camera setups improvised in homes and clinics. This method kept the design process moving but also proved efficient, yielding insights that later shaped a published framework for hybrid research in medical contexts.
final prototype series in folded condition
3FOLD in the application process of the Hylomate pouch to a pacemaker
film still of the application process in the operating room
manual prototype production
animation still from the 3FOLD packaging process
the design process draws inspiration from origami, kirigami, and auxetic structures
rendering of the folded application instrument
prototype production using the Zünd flatbed plotter
Hylomate is a biocompatible pouch that wraps the implant to safeguard the body
project info:
name: 3FOLD
designer: Laurin Schaffner & Benjamin Relly
project partner: Hylomorph AG
financing: Innosuisse – Schweizerische Agentur für Innovationsförderung
team: Nicole Kind, Aldo Ferrari, Simone Bottan, Francesco Robotti, Lisa Ochsenbein
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edited by: thomai tsimpou | designboom