Three-dimensional folding of pre-strained polymer sheets via absorption of laser light

Patterned light from a laser can induce rapid self-folding of pre-strained polymer sheets. Black ink coated on the sheet absorbs the light, which converts the photon energy into thermal energy that heats the sheet locally; the temperature of the sheet is highest at the surface where the light impinges on the sheet and decreases through the sheet thickness. The gradient of temperature induces a gradient of strain relaxation through the depth of the sheet, which causes folding within seconds of irradiation. The pattern of laser light that irradiates the compositionally homogeneous two-dimensional (2D) substrate dictates the resulting three-dimensional (3D) shape. Unlike most approaches to self-folding, the methodology described here requires no patterning of pre-defined hinges. It opens up the possibility of using a patterning technique that is inherently 2D to form 3D shapes. The use of lasers also enables systematic control of key process parameters such as power, intensity, and the pattern of light (i.e., beam width and shape). The rate of folding and folding angle measured with respect to these parameters provide an indirect quantification of heat loss in the sample and thereby identify the threshold power and power intensity that must be delivered to the hinge for folding to occur. (C) 2014 AIP Publishing LLC.