This article explores the artful application of pleats in theatrical costume design.From a comprehensive perspective blending morphology and craftsmanship,the study systematically analyzes how pleats in theatrical costumes carry functional roles and exhibit unique artistic expressions.Emphasizing the multidimensional visual potency and limitless innovative potential of pleats,the research highlights their role as mediators of emotions,effectively externalizing the character's personality traits and inner feelings into form.Thus,pleats serve as a resonant bridge between theatrical costume design,character portrayal,and audience emotions.