Abstract
Thin fiber reinforced polymer (FRP) composites are widely implemented in adaptive and morphing structures. However, realization of the necessary complex 3-dimensional FRP structures requires the use of expensive molds thereby limiting the design space and flexibility. Using the elastic strain energy of pre-stretched membranes holds potential for addressing this challenge. In this work, a novel manufacturing technique for fabricating 3-dimensional FRP structures moldlessly is presented where pre-stretched membranes are used to drive out-of-plane buckling instabilities of FRP composite shells. To explore the potential of this approach, a simple square frame design is investigated. An analytical model based on high deformation beam buckling theory is developed for understanding the parameters driving the out-of-plane behavior of these structures. Experimental and finite element results are used for model validation and reveal excellent agreement, with errors less than 10% over a large portion of the design space. Analytical and finite element models demonstrate that the out-of-plane deformation can be tailored by varying the structure’s geometric and material parameters. A new design space for FRP composite laminates is characterized, enabling highly flexible design. The manufacturing and modeling techniques can be extended to other geometries for the realization and analysis of arbitrarily complex surfaces.
Highlights
Complex 3D topologies, such as those proposed for mechanical metamaterial concepts, have sparked the advancement of a broad range of engineering applications in the field of adaptive, morphing, and deployable structures
Singly or doubly curved shapes obtained by the thermal effect suffer from low curvatures ‐ drastically restricting the range of application of the thin fiber reinforced polymer (FRP) laminates generated by this process
The results show less than 10% error, indicating that the analytical model can successfully capture the mechanics of the structure
Summary
Complex 3D topologies, such as those proposed for mechanical metamaterial concepts, have sparked the advancement of a broad range of engineering applications in the field of adaptive, morphing, and deployable structures. Singly or doubly curved shapes obtained by the thermal effect suffer from low curvatures ‐ drastically restricting the range of application of the thin FRP laminates generated by this process Another class of self‐shaping concepts, of particular interest for the scope of this work, relies on elastic instabilities [15]. Reversible wrinkle patterns have been created on silk/polydimethylsiloxane bilayer structures [16] and controlled buckling patterns have been investigated by combining thin metal films with elastomeric polymers [17] In this case, surface instability is induced by thermal contraction of one of the constituents. Ruslan et al [28] utilized pre‐stretched elastic sheets combined with an anisotropic distribution of disconnected rigid tiles and presented an approximate model that allows the realization of targeted doubly curved surfaces fabricated as a flat piece. Architects combined 3D printed polylactide (PLA) with a pre‐stretched textile for the realization of self‐shaping shoes [29] or building covers [30]
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