Rhode Island-based studio Pneuhaus has pioneered a new inflatable panelling system for extraterrestrial architecture featured in AppleTV’s upcoming Murderbot series. Collaborating with production designer Sue Chan, Pneuhaus designed and fabricated over 400 triangular inflatable cushions made from flexible Thermoplastic Polyurethane (TPU) for the show’s futuristic habitat sets.
These airtight, cellular modules clad key structures, including the central pill-shaped PresAux habitat, where the panels were draped over a wood framework. Designed for visual versatility—ranging from translucent to opaque finishes—the units were also durable enough to withstand full-body impact during filming.
Unlike conventional materials such as vacuformed plexiglass or PVC, the TPU cushions are lighter, tear-resistant, and recyclable, offering a sustainable and cost-effective alternative that enabled greater freedom in set design. The cushions were RF-welded (radio-frequency welded), a method using electromagnetic current to bond thermoplastics, allowing fast and precise production.
Chan emphasized that this technique, inspired by tensile membrane architecture such as Cloud 9’s Media-ICT building, allowed the team to avoid compromises in set size and realism. “Using Pneuhaus’ inflatable technology has not been done before in set construction,” Chan stated. “It let us build a fuller, more authentic environment.”
The result is an innovative construction system that aligns with both sci-fi aesthetics and sustainable design principles, offering a speculative vision of how real-world architecture might evolve in space habitats of the future.
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