Topologically Variable and Volumetric Morphing of 3D Architected Materials with Shape Locking

Abstract: The morphing of 3D structures is suitable for i) future tunable material design for customizing material properties and ii) advanced manufacturing tools for fabricating 3D structures on a 2D plane. However, there is no inverse design method for topologically variable and volumetric morphing or morphing with shape locking, which limits practical engineering applications. In this study, we construct a general inverse design method for 3D architected materials for topologically variable and volumetric morphing, whose shapes are lockable in the morphed states, which can contribute to future tunable materials, design, and advanced manufacturing. Volumetric mapping of bistable unit cells onto any 3D morphing target geometry with kinematic and kinetic modifications can produce flat-foldable and volumetric morphing structures with shape-locking. This study presents a generalized inverse design method for 3D metamaterial morphing that can be used for structural applications with shape locking. Topologically variable morphing enables the manufacture of volumetric structures on a 2D plane, saving tremendous energy and materials compared with conventional 3D printing. Volumetric morphing can significantly expand the design space with tunable physical properties without limiting the selection of base materials.