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Design of super-conformable, foldable materials via fractal cuts and lattice kirigami

Published online by Cambridge University Press:  11 February 2016

Shu Yang
Affiliation:
Department of Materials Science and Engineering, University of Pennsylvania, USA; shuyang@seas.upenn.edu
In-Suk Choi
Affiliation:
High Temperature Energy Materials Research Center, Korea Institute of Science and Technology, South Korea; insukchoi@kist.re.kr
Randall D. Kamien
Affiliation:
Department of Physics and Astronomy, University of Pennsylvania, USA; kamien@physics.upenn.edu

Abstract

Materials that can expand and collapse, fold, and transform into a variety of shapes have attracted significant interest and have applications in the design of flexible electronics, color displays, smart windows, actuators, sensors, and both photonic and phononic devices. But how can we render a rigid device super-flexible so that it can wrap around a sphere without bending and stretching? How can flat surfaces be transformed into any desired three-dimensional (3D) structure without disruptive or catastrophic deformation? The key lies in cuts. Here, we review recent research progress in the design of super-conformable and foldable materials by employing fractal cutting and lattice-based kirigami elements that combine cutting and folding. By prescribing cuts with different motifs, identifying edges in the right geometry, and by programming the folding directions, we show that a single flat sheet can be transformed into a variety of targeted 2D and 3D structures—a pluripotent platform for new technologies.

Information

Type
Research Article
Copyright
Copyright © Materials Research Society 2016 
Figure 0

Figure 1. (a) Basic deformation principles behind the patterns of the cuts. Cuts divide the material into rotating units. Upon equal biaxial stretching, each unit rotates clockwise (white arrows) or counterclockwise (yellow arrows), (b) by bending a finite hinge (width, w; height, h) so that the original structure expands. A square rotating unit of length L is shown. (c) Finite element calculations of silicone rubber sheets with multilevel hierarchical cuts are given.65

Figure 1

Figure 2. The two cut motifs, α (red) and β (blue) in a hierarchical structure and diverse combinations of the hierarchy (or number of levels) and motifs (a–d).65

Figure 2

Figure 3. Macroscopic experimental realization of a fractal cut concept. The shape changes of silicone rubber sheets stretched with patterned cuts in Figure 2a–d are identical to those seen from the finite element calculations. The smallest feature size (hinge width) is 2 mm. (e) Photo of a stretchable electrode embedded with ε3(ααα) fractal cuts in a silicone rubber sheet coated with a thin conducting film, and conformable wrapping of the structure around a baseball without wrinkles. The green LED light remains lit after wrapping. Scale bar: 40 mm.65

Figure 3

Figure 4. Poly(dimethylsiloxane) sheets differentiated with microscopic patterned cuts. The smallest feature size (hinge width) is 40 μm. (a) One unit of the homogeneous structure notated as ε4(αααα). (b) One unit of the ε4(βαβα) structure. (εi represents the maximum possible strain of a struture with i levels of cut motifs α or β). Scale bar: 200 μm.65

Figure 4

Figure 5. Flat distorted sheets of a triangular lattice buckling into the third dimension. (Left) A fivefold defect (a “5”) buckles into a positive Gaussian curvature surface to relieve strain (note that the struts are more regular). (Right) A sevenfold defect (a “7”) buckles into a saddle with negative Gaussian curvature. Courtesy of H.S. Seung and D.R. Nelson.

Figure 5

Figure 6. The essence of kirigami. (a) The climb cut, where two dislocations are separated by a climb. Top: We remove the hatched region and make mountain (M) and valley (V) folds along the indicated lines. The yellow regions have become pentagons, the green regions heptagons. Bottom: Final state with the edges of the cut identified by pasting. (b) The glide cut. We remove the hatched regions and make a cut along the ratchet, then make |M| and |V| folds along the indicated lines, followed by gliding of the triangles along the ratchet to the final form. The ratchet allows for interlocking of the final folded structure without the need for pasting.

Figure 6

Figure 7. Top, a two-level kirigami fold motif that can be distorted through rigid folding into a three-level structure with “0,” “1,” and “2” (bottom) indicating different elevations. The three-level structure, however, has a threefold degeneracy that can be exploited to generate arbitrary topographies as seen in Figure 8 and in Reference 67, depending on the local assignment of the fold direction, thus the level of elevation. The blue lines depict the line along which the final fold is made. The three different choices of fold lines are labeled α, β, and γ.

Figure 7

Figure 8. Demonstration of the pluripotent design capability of the sixon lattice. Starting from the base configuration of a 151 × 151 grid of triangular plateaus, a target surface is first selected (e.g., a monkey saddle or Mt. Katahdin). The height of this target surface is projected onto the grid of triangular patches, and from this a local sequence of fold assignments is made to construct the final kirigami structure.67