SIM-AM 2025

3D Printing challenges and design strategies for multistable origami structures

  • Mora, Samantha (University of Trento)
  • Pugno, Nicola (University of Trento)
  • Misseroni, Diego (University of Trento)

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Origami-inspired engineering enables the design of multistable structures, with Kresling origami offering programmable energy landscapes. While 3D printing facilitates their fabrication, transitioning from paper models to photopolymer-based structures presents challenges due to manufacturing constraints and the visco-hyperelastic nature of these materials. We investigate how crease geometry and material properties influence bistability in 3D-printed Kresling cells through experiments, numerical simulations, and material characterization. Reducing internal crease thickness using reduction factors (RF) enhances bistability, with cross-section reductions over 50% despite fabrication limitations. Bistability strongly depends on the relaxation modulus: higher values compromise it, while lower values preserve bistability across time scales. Crease cross-section modifications significantly impact energy landscapes, mitigating visco-hyperelastic effects, particularly in thinner configurations. Moreover, we explore monomaterial Kresling cells with void-patterned creases, which improve energy storage and tunable deformation. Materials with intermediate stiffness (E~600MPa) are potentially optimal for bistable, foldable designs, particularly in microfabrication. Adjusting crease stiffness in monostable assemblies enables programmable energy landscapes and controlled deformation. Our findings address key 3D printing challenges and expand the application of origami-inspired structures in programmable energy absorbers, deployable robotics, and tunable actuators. By leveraging advanced 3D printing and refined FEA models, we enhance bistability control and energy landscape design, paving the way for new multistable engineered systems in both micro- and macro-fabrication.