A Systematic Framework for the Design & Manufacturing of Voxel-Based Multi-material Thick Folding Origami

Research Poster Engineering 2025 Graduate Exhibition

Presentation by Evelyn Thomas

Exhibition Number 34

Abstract

Origami enables the design of complex mechanical systems, realizing these systems in thick, engineered materials require additional design and manufacturing considerations when contrasted against traditional, paper-thin origami. Methods to accommodate for thickness in origami-based systems traditionally require numerous processes and assembly steps. The material and functional complexity of voxel-based additive manufacturing can address the drawbacks inherent to traditional thick-folding origami. Design at the voxel level can allow for precise and continuous functionally-graded material properties that enable novel behavior and improve the overall performance of thick-folding origami designs. The complexities inherent to voxel-based design, additive manufacturing, and thick-folding origami-based mechanism design compound challenges the of designing and manufacturing these parts. This paper details a framework that unites these fields to enable the design of voxel-based additive-manufactured thick-folding origami parts. The framework is composed of three major categories: geometric, material, and printing considerations that make the formation of thick-folding origami using voxel-based multi-material additive manufacturing possible. This framework is demonstrated through four case studies that show the application of voxel-based multi-material additive manufacturing to thick-folding origami techniques.

Importance

This work provides a framework for designing thick-folding origami-based mechanisms (OBMs). These mechanisms require rigid and flexible regions to move between compact and expanded forms. Multi-material additive manufacturing (MMAM) allows for 1-part, 1-process production of these mechanisms. Voxel-based design enables functional grading that can reduce shear at the interfaces between dissimilar materials. Material properties can be assigned at the 0.0033” x 0.0033” x 0.0007” (0.085mm x 0.085mm x 0.01875mm) scale. This framework is significant because it manages the complexities of MMAM, voxel-based design, and mathematical principles inherent to thick-folding OBMs. This empowers designers to produce more efficient thick-folding origami-based mechanisms without compromising range of motion.

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