Invention Reference Number
Manufacturing large composite structures presents challenges related to cost, time and mold complexity. This novel approach leverages multi-functional materials and stiffness-based architectures to transform flat structures into complex 3D surfaces without the need for large molds. Inspired by origami and kirigami principles, this technology enables rapid, scalable production of intricate geometries for a variety of industries.
Description
This method integrates additive manufacturing and folding-based design to create morphing structures from flat materials. By layering flexible and rigid materials in strategic patterns, the technology enables controlled curvature and structural stability. A base layer of flexible material serves as a continuous surface, while varying thicknesses and geometries of rigid material define stiffness and shape transformation. This eliminates the need for traditional mold-based fabrication, significantly reducing production time. The approach is adaptable to sheet metal, polymer composites and other materials, offering a scalable, cost-effective solution for producing large, complex structures.
Benefits
- Eliminates need for large molds, reducing manufacturing costs and complexity
- Enables rapid production, significantly reducing build time compared to conventional methods
- High scalable, adaptable for applications requiring large, intricate geometries
- Supports multiple materials, enhancing structural performance and design flexibility
Applications and Industries
- Aerospace and marine manufacturing: Creation of lightweight, durable structures
- Architectural design: Development of foldable and morphing building components
- Rapid deployable structures: Advanced solutions for temporary shelters and modular construction
- Automotive and industrial fabrication: Efficient large-scale part production
Contact
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
