In the 21st century, the fashion industry is being urged to transform from a traditional product-oriented model to a sustainable, human-centric system. Industry 5.0, which emphasizes human-centricity, sustainability, and system resilience, is redefini...
In the 21st century, the fashion industry is being urged to transform from a traditional product-oriented model to a sustainable, human-centric system. Industry 5.0, which emphasizes human-centricity, sustainability, and system resilience, is redefining industrial paradigms, demanding structural innovation beyond the mass production–consumption cycle. In this context, the present study proposed a new upcycling fashion design system by integrating modular design principles with digital technologies such as CLO 3D and virtual reality (VR).
Traditional upcycling design, while creative, has remained largely manual and non-standardized, limiting scalability and systematization. This study aimed to overcome these limitations by applying modular design to develop structurally recombinable prototypes and to utilize digital platforms for simulation, evaluation, and iterative feedback. The research objectives were threefold: (1) to analyze the theoretical applicability of modular design in fashion; (2) to develop a modular upcycling dress prototype using CLO 3D based on a men's shirt; and (3) to
conduct user-centered design evaluation using immersive VR environments.
The results confirmed that modular design enabled efficient reconfiguration and reproducibility, transforming handcrafted upcycling into a digitally supported, system-driven process. The five-phase strategy developed—(1) modular
configuration, (2) color block application, (3) VR-based evaluation, (4) design optimization, and (5) system structuring—functioned as a circulatory model that connected design, feedback, and refinement. User evaluations in the VR
environment provided multidimensional feedback, including structural clarity, immersive experience, and design completeness, demonstrating the potential of VR as a consumer-driven evaluation tool beyond static visual assessments.
This study contributed a theoretical and practical framework for sustainable upcycling fashion in the digital age. First, by introducing modularity into fashion structure analysis, it presented a design logic that allowed structural unitization and recombination. Second, the integration of CLO 3D and VR enabled a dynamic
design evaluation model based on user perception, shifting the paradigm from static observation to experiential interaction. Third, the proposed strategy established a repeatable digital prototype system that minimized fabric waste and enhanced design efficiency, suggesting the feasibility of Industry 5.0–oriented fashion systems.
Nevertheless, the study had several limitations. The VR evaluation was conducted mainly with fashion design students, lacking diversity in consumer representation.
Furthermore, VR technology had constraints in simulating tactile feedback, lighting variations, and high-fidelity texture representations. The sample size and number of evaluated designs were also limited, which may restrict the generalizability of the findings. Future research should involve diverse user groups, enhance modular data integration between CLO 3D and VR, and apply quantitative modeling for in-depth psychological analysis. These efforts would help evolve the proposed framework into a more refined, consumer-participatory digital ecosystem for sustainable fashion.