4D Origami by Smart Embroidery

There exist many methods for processing of materials: extrusion, injection molding, fibers spinning, 3D printing, to name a few. In most cases, materials with a static, fixed shape are produced. However, numerous advanced applications require customized elements with reconfigurable shape. The few available techniques capable of overcoming this problem are expensive and/or time-consuming. Here, the use of one of the most ancient technologies for structuring, embroidering, is proposed to generate sophisticated patterns of active materials, and, in this way, to achieve complex actuation. By combining experiments and computational modeling, the fundamental rules that can predict the folding behavior of sheets with a variety of stitch-patterns are elucidated. It is demonstrated that theoretical mechanics analysis is only suitable to predict the behavior of the simplest experimental setups, whereas computer modeling gives better predictions for more complex cases. Finally, the applicability of the rules by designing basic origami structures and wrinkling substrates with controlled thermal insulation properties is shown.