Programming stiff inflatable shells from planar patterned fabrics

Active Fabrics With Controllable Stiffness for Robotic Assistive Interfaces

Assistive interfaces enable collaborative interactions between humans and robots. In contrast to traditional rigid devices, conformable fabrics with tunable mechanical properties have emerged as compelling alternatives. However, existing assistive fabrics actuated by fluidic or thermal stimuli struggle to adapt to complex body contours and are hindered by challenges such as large volumes after actuation and slow response rates. To overcome these limitations, inspiration is drawn from biological protective organisms combining hard and soft phases, and active assistive fabrics consisting of architectured rigid tiles interconnected with flexible actuated fibers are proposed. Through programmable tessellation of target body shapes into architectured tiles and controlling their interactions by the actuated fibers, the active fabrics can rapidly transition between soft compliant configurations and rigid states conformable to the body (>350 times stiffness change) while minimizing the device volume after actuation. The versatility of these active fabrics is demonstrated as exosuits for tremor suppression and lifting assistance, as body armors for impact mitigation, and integration with electrothermal actuators for smart actuation with convenient folding capabilities. This work offers a practical framework for designing customizable active fabrics with shape adaptivity and controllable stiffness, suitable for applications in wearable exosuits, haptic devices, and medical rehabilitation systems.

Viscoelastic dynamics of a soft strip subject to a large deformation

To produce sounds, we adjust the tension of our vocal folds to shape their properties and control the pitch. This efficient mechanism offers inspiration for designing reconfigurable materials and adaptable soft robots. However, understanding how flexible structures respond to a significant static strain is not straightforward. This complexity also limits the precision of medical imaging when applied to tensioned organs like muscles, tendons, ligaments and blood vessels among others. In this article, we experimentally and theoretically explore the dynamics of a soft strip subject to a substantial static extension, up to 180%. Our observations reveal a few intriguing effects, such as the resilience of certain vibrational modes to a static deformation. These observations are supported by a model based on the incremental displacement theory. This has promising practical implications for characterizing soft materials but also for scenarios where external actions can be used to tune properties.

Pneumatic cells toward absolute Gaussian morphing

On a flat map of the Earth, continents are inevitably distorted. Reciprocally, curving a plate simultaneously in two directions requires a modification of in-plane distances, as Gauss stated in his seminal theorem. Although emerging architectured materials with programmed in-plane distortions are capable of such shape morphing, an additional control of local bending is required to precisely set the final shape of the resulting three-dimensional surface. Inspired by bulliform cells in leaves of monocotyledon plants, we show how the internal structure of flat panels can be designed to program bending and in-plane distortions simultaneously when pressurized, leading to a targeted shell shape. These surfaces with controlled stiffness and fast actuation are manufactured using consumer-grade materials and open a route to large-scale shape-morphing robotics applications.

Turing pattern-based design and fabrication of inflatable shape-morphing structures

Turing patterns are self-organizing stripes or spots widely found in biological systems and nature. Although inspiring, their applications are limited. Inflatable shape-morphing structures have attracted substantial research attention. Traditional inflatable structures use isotropic materials with geometrical features to achieve shape morphing. Recently, gradient-based optimization methods have been used to design these structures. These methods assume anisotropic materials whose orientation can vary freely. However, this assumption makes fabrication a considerable challenge by methods such as additive manufacturing, which print isotropic materials. Here, we present a methodology of using Turing patterns to bridge this gap. Specifically, we use Turing patterns to convert a design with distributed anisotropic materials to a distribution with two materials, which can be fabricated by grayscale digital light processing 3D printing. This work suggests that it is possible to apply patterns in biological systems and nature to engineering composites and offers new concepts for future material design.

Flow-network-controlled shape transformation of a thin membrane through differential fluid storage and surface expansion

The mechanical properties of a thin, planar material, perfused by an embedded flow network, have been suggested to be potentially changeable locally and globally by fluid transport and storage, which can result in both small- and large-scale deformations such as out-of-plane buckling. In these processes, fluid absorption and storage eventually cause the material to locally swell. Different parts can hydrate and swell unevenly, prompting a differential expansion of the surface. In order to computationally study the hydraulically induced differential swelling and buckling of such a membrane, we develop a network model that describes both the membrane shape and fluid movement, coupling mechanics with hydrodynamics. We simulate the time-dependent fluid distribution in the flow network based on a spatially explicit resistor network model with local fluid-storage capacitance. The shape of the surface is modeled by a spring network produced by a tethered mesh discretization, in which local bond rest lengths are adjusted instantaneously according to associated local fluid content in the capacitors in a quasistatic way. We investigate the effects of various designs of the flow network, including overall hydraulic traits (resistance and capacitance) and hierarchical architecture (arrangement of major and minor veins), on the specific dynamics of membrane shape transformation. To quantify these effects, we explore the correlation between local Gaussian curvature and relative stored fluid content in each hierarchy by using linear regression, which reveals that stronger correlations could be induced by less densely connected major veins. This flow-controlled mechanism of shape transformation was inspired by the blooming of flowers through the unfolding of petals. It can potentially offer insights for other reversible motions observed in plants induced by differential turgor and water transport through the xylem vessels, as well as engineering applications.

Bending stiffness of Candida albicans hyphae as a proxy of cell wall properties

The cell wall is a key component of fungi. It constitutes a highly regulated viscoelastic shell which counteracts internal cell turgor pressure. Its mechanical properties thus contribute to define cell morphology. Measurements of the elastic moduli of the fungal cell wall have been carried out in many species including Candida albicans, a major human opportunistic pathogen. They mainly relied on atomic force microscopy, and mostly considered the yeast form. We developed a parallelized pressure-actuated microfluidic device to measure the bending stiffness of hyphae. We found that the cell wall stiffness lies in the MPa range. We then used three different ways to disrupt cell wall physiology: inhibition of beta-glucan synthesis, a key component of the inner cell wall; application of a hyperosmotic shock triggering a sudden decrease of the hyphal diameter; deletion of two genes encoding GPI-modified cell wall proteins resulting in reduced cell wall thickness. The bending stiffness values were affected to different extents by these environmental stresses or genetic modifications. Overall, our results support the elastic nature of the cell wall and its ability to remodel at the scale of the entire hypha over minutes.

Methods for numerical simulation of knit based morphable structures: knitmorphs

Shape morphing behavior has applications in many fields such as soft robotics, actuators and sensors, solar cells, tight packaging, flexible electronics, and biomedicine. The most common approach to achieve shape morphing structures is through shape memory alloys or hydrogels. These two materials undergo differential strains which generate a variety of shapes. In this work, we demonstrate the novel concept that 2D knits comprising of yarns from different materials can be morphed into different three-dimensional shapes thereby forming a bridge between traditional knitting and shape changing structures. This concept is referred to as Knitmorphs. Our computational analysis acts as the proof of concept revealing that knitted patterns of varying materials morph into complex shapes, such as saddle, axisymmetric cup, and a plate with waves when subjected to thermal loads. Two-dimensional circular models of plain and rib developed on CAD packages are imported to the finite element analysis software Abaqus, followed by post-processing into wires and assigning fiber material properties of different thermal coefficients of expansion and stiffness. We also propose potential applications for the concept of programmable knits for developing robots based upon jellyfish like locomotion, and complex structures similar to wind turbine blades. This novel concept is meant to introduce a new field for design when considering morphable structures.

Shaping by Internal Material Frustration: Shifting to Architectural Scale

Self-morphing of thin plates could greatly impact the life if used in architectural context. Yet, so far, its realizations are limited to small-scale structures made of model materials. Here, new fabrication techniques are developed that turn two conventional construction materials-clay and fiber composites (FRP)-into smart, self-morphing materials, compatible with architectural needs. Controlled experiments verify the quantitative connection between the prescribed small-scale material structure and the global 3D surface, as predicted by the theory of incompatible elastic sheets. Scaling up of desired structures is demonstrated, including a method that copes with self-weight effects. Finally, a method for the construction of FRP surfaces with complex curvature distribution is presented, together with a software interface that allows the computation of the 3D surface for a given fiber pattern (the forward problem), as well as the fiber distribution required for a desired 3D shape (the inverse problem). This work shows the feasibility of large-scale self-morphing surfaces for architecture.

Curvature Induced by Deflection in Thick Meta-Plates

The design of advanced functional devices often requires the use of intrinsically curved geometries that belong to the realm of non-Euclidean geometry and remain a challenge for traditional engineering approaches. Here, it is shown how the simple deflection of thick meta-plates based on hexagonal cellular mesostructures can be used to achieve a wide range of intrinsic (i.e., Gaussian) curvatures, including dome-like and saddle-like shapes. Depending on the unit cell structure, non-auxetic (i.e., positive Poisson ratio) or auxetic (i.e., negative Poisson ratio) plates can be obtained, leading to a negative or positive value of the Gaussian curvature upon bending, respectively. It is found that bending such meta-plates along their longitudinal direction induces a curvature along their transverse direction. Experimentally and numerically, it is shown how the amplitude of this induced curvature is related to the longitudinal bending and the geometry of the meta-plate. The approach proposed here constitutes a general route for the rational design of advanced functional devices with intrinsically curved geometries. To demonstrate the merits of this approach, a scaling relationship is presented, and its validity is demonstrated by applying it to 3D-printed microscale meta-plates. Several applications for adaptive optical devices with adjustable focal length and soft wearable robotics are presented.

Multistable inflatable origami structures at the metre scale

From stadium covers to solar sails, we rely on deployability for the design of large-scale structures that can quickly compress to a fraction of their size^1-4. Historically, two main strategies have been used to design deployable systems. The first and most frequently used approach involves mechanisms comprising interconnected bar elements, which can synchronously expand and retract^5-7, occasionally locking in place through bistable elements^8,9. The second strategy makes use of inflatable membranes that morph into target shapes by means of a single pressure input^10-12. Neither strategy, however, can be readily used to provide an enclosed domain that is able to lock in place after deployment: the integration of a protective covering in linkage-based constructions is challenging and pneumatic systems require a constant applied pressure to keep their expanded shape^13-15. Here we draw inspiration from origami-the Japanese art of paper folding-to design rigid-walled deployable structures that are multistable and inflatable. Guided by geometric analyses and experiments, we create a library of bistable origami shapes that can be deployed through a single fluidic pressure input. We then combine these units to build functional structures at the metre scale, such as arches and emergency shelters, providing a direct route for building large-scale inflatable systems that lock in place after deployment and offer a robust enclosure through their stiff faces.

Harnessing Mechanical Deformation to Reduce Spherical Aberration in Soft Lenses

Mechanical deformation has recently emerged as a promising platform to realize optical devices with tunable response. While most studies to date have focused on the tuning of the focal length, here we use a combination of experiments and analyses to show that an applied tensile strain can also largely reduce spherical aberration. We first demonstrate the concept for a cylindrical elastomeric lens and then show that it is robust and valid over a range of geometries and material properties. As such, our study suggests that large mechanical deformations may provide a simple route to achieve the complex profiles required to minimize aberration and realize lenses capable of producing images of superior quality.

Shape Programming by Modulating Actuation over Hierarchical Length Scales

Many active materials used in shape-morphing respond to an external stimulus by stretching or contracting along a director field. The programming of such actuators remains complex because of the single degree of freedom (the orientation) in local actuation. Here, texturing this field in zigzag patterns is shown to provide an extended family of biaxial active stretches out of an otherwise single uniaxial active deformation, opening a larger parameter space. By further modulating the zigzag patterns at the larger scale of the structure, its deployed shape can be controlled. This notion of texturing over hierarchical length scales follows geometrical principles, and is robust against changes in size and materials. The robustness of the approach is demonstrated by considering three different responsive materials: inextensible flat fabrics, channel-bearing elastomer (respectively, contracting and expanding perpendicularly to the director field when actuated pneumatically), and 3D-printed thermoplastic (composed of extruded filaments that contract when heated). It is shown that large-scale shape-morphing structures can be generated and that their geometry can be controlled with high accuracy.

Inflationary routes to Gaussian curved topography

Gaussian-curved shapes are obtained by inflating initially flat systems made of two superimposed strong and light thermoplastic impregnated fabric sheets heat-sealed together along a specific network of lines. The resulting inflated structures are light and very strong because they (largely) resist deformation by the intercession of stretch. Programmed patterns of channels vary either discretely through boundaries or continuously. The former give rise to faceted structures that are in effect non-isometric origami and that cannot unfold as in conventional folded structures since they present the localized angle deficit or surplus. Continuous variation of the channel direction in the form of spirals is examined, giving rise to curved shells. We solve the inverse problem consisting in finding a network of seam lines leading to a target axisymmetric shape on inflation. They too have strength from the metric changes that have been pneumatically driven, resistance to change being met with stretch and hence high forces like typical shells.