Programmable Deployable Structures

Abstract

This study presents a computational and experimental framework for translating arbitrary doubly curved surfaces into 3D-printed, deployable structures based on programmable mechanical metamaterials. A rotating-polygon auxetic lattice is employed for its ability to expand or contract while preserving in-plane geometry. A dynamic-relaxation workflow implemented in Grasshopper/Kangaroo links flattened and target configurations through a global equal-length constraint, automatically resolving element dimensions and hinge rotations. This approach is validated on test shapes with three types of curvature: mono-, syn-, and anticlastic. Physical models of these test shapes were printed to demonstrate the feasibility of the method.
In addition, the potential for scaling the system to full-scale structures was explored through large-format additive manufacturing. Deployment techniques were investigated, and discussions with industry experts informed decisions on manufacturability and material selection. Full-scale printing trials were conducted to balance the flexibility required for compliant hinges with the rigidity needed in structural elements.
Finally, the developed method was applied to a case study: a temporary shelter for festivals and events. A deployable design was created, and optimisation strategies were explored for both the surface geometry and the applied lattice grid. Finite element analyses were performed to evaluate deformations during deployment as well as structural performance under operational loads. A 1:10 scale prototype was constructed to illustrate how the structure can be divided into printable segments and assembled to form the complete system.