Directed Shape Morphing using Kirigami-enhanced Thermoplastics

Abstract: We present a simple, accessible method for autonomously transforming flat plastic sheets into intricate three-dimensional structures using only uniform heating and common tools such as household ovens and scissors. Our approach combines heat-shrinkable thermoplastics with Kirigami patterns tailored to the target 3D shape, creating bilayer composites that morph into a wide range of complex structures, e.g., bowls, pyramids, and even custom ergonomic surfaces like mouse covers. Critically, the transformation is driven by a low-information stimulus (uniform heat) yet produces highly intricate shapes through programmed geometric design. The morphing behavior, confirmed by finite element simulations, arises from strain mismatch between the contracting thermoplastic layer and the constraining Kirigami layer. By decoupling material composition from mechanical response, this method avoids detailed process control and enables a broad class of self-morphing structures, offering a versatile platform for adaptive design and scalable manufacturing.