Multimaterial 3D printed self-locking thick-panel origami metamaterials

Thick-panel origami has shown great potential in engineering applications. However, the thick-panel origami created by current design methods cannot be readily adopted to structural applications due to the inefficient manufacturing methods. Here, we report a design and manufacturing strategy for creating thick-panel origami structures with excellent foldability and capability of withstanding cyclic loading. We directly print thick-panel origami through a single fused deposition modeling (FDM) multimaterial 3D printer following a wrapping-based fabrication strategy where the rigid panels are wrapped and connected by highly stretchable soft parts. Through stacking two thick-panel origami panels into a predetermined configuration, we develop a 3D self-locking thick-panel origami structure that deforms by following a push-to-pull mode enabling the origami structure to support a load over 11000 times of its own weight and sustain more than 100 cycles of 40% compressive strain. After optimizing geometric parameters through a self-built theoretical model, we demonstrate that the mechanical response of the self-locking thick-panel origami structure is highly programmable, and such multi-layer origami structure can have a substantially improved impact energy absorption for various structural applications. Thick panel origami holds great potential in engineering structures, but conventional fabrication processes limit their design and applications. Here the authors report a multimaterial 3D printing-based design and fabrication strategy for thick-panel origami structures with push-to-pull deformation.

Automated summary

Conventional design methods for thick-panel origami structures are inefficient in manufacturing, hindering their adoption in structural applications. In this study, a design and manufacturing strategy is proposed to create thick-panel origami structures using a single multimaterial 3D printer. The structures are designed through a wrapping-based fabrication strategy, with rigid panels wrapped and connected by stretchable soft parts. By stacking two thick-panel origami panels, a self-locking structure is formed, capable of withstanding over 11000 times its own weight and enduring more than 100 cycles of 40% compressive strain. Through optimization, the mechanical response of the self-locking thick-panel origami structure can be programmed, leading to improved impact energy absorption for various structural applications.