Geometric characteristics, deployment mechanisms, and digital fabrication methods of a free-form deployable membrane system based on CNC-knitted fabrics and CNC-bent frames

Deployable membrane structures have played a vital role in creating flexible and adaptable urban and architectural spaces. However, the geometries of deployable membrane structures are often confined to symmetrical and regular shapes, due to the complex interdependencies between structure, material, motion, and geometry. To overcome this challenge, this research proposes a new category of deployable membrane structures that enables a broad range of deployment geometries, including free forms. The proposed system facilitates the transformation of arbitrary free-form surfaces into structural models, simplifies kinematic analysis for free-form deployment, and reduces structural calculations for free-form deployable structures. This study systematically investigated the proposed deployable membrane system in terms of geometric characteristics, deployment mechanisms, and digital manufacturing methods, including investigations of the generation method and geometric categories, summarizations of the folding mode and foldability conditions, and explorations of the CNC manufacturing logic and the G-code generation method. Finally, a full-scale physical prototype is studied to validate the proposed system and related methods.

Automated summary

Deployable membrane structures are crucial for creating flexible and adaptable urban and architectural spaces. However, their geometries are often limited to symmetrical and regular shapes. To address this challenge, this research proposes a new category of deployable membrane structures that allows for a broad range of free form deployment geometries.