Pop-up assembly of 3D structures actuated by heat shrinkable polymers

Abstract

Folding 2D sheets into desired 3D structures is a promising fabrication technique that can find a wide range of applications. Compressive buckling provides an attractive strategy to actuate the folding and can be applied to a broad range of materials. Here a new and simple method is reported to achieve controlled compressive buckling, which is actuated by a heat shrinkable polymer sheet. The buckling deformation is localized at the pre-defined creases in the 2D sheet, resulting in sharp folding. Two approaches are developed to actuate the transformation, which follow similar geometric rules. In the first approach, the 2D precursor is pushed from outside, which leads to a 3D structure surrounded by the shrunk polymer sheet. Assembled 3D structures include prisms/pyramids with different base shapes, house roof, partial soccer ball, Miura-ori structure and insect wing. In the second approach, the 2D precursor is pulled from inside, which leads to a 3D structure enclosing the shrunk polymer sheet. Prisms/pyramids with different base shapes are assembled. The assembled structures are further tessellated to fabricate cellular structures that can be used as thermal insulator and crash energy absorber. They are also stacked vertically to fabricate complex multilayer structures.