Advanced 3D Printing Creates Origami-Inspired Structures

Researchers at Oak Ridge National Laboratory have developed a hybrid additive manufacturing technique that combines origami-inspired design with composite materials to create mold-free, foldable structures. By depositing reinforcing materials directly onto flexible fabrics, the process allows for the creation of complex three-dimensional forms from flat-printed panels. This innovation significantly reduces production costs and lead times, offering a scalable solution for large-scale composite manufacturing across various industrial sectors.

Lead researcher Steven Guzorek and his team at Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility have introduced a method that integrates material science with transformative design to produce lightweight, cost-efficient structures. The process involves depositing a bonding layer, such as thermoplastic polyurethane, onto a high-strength fabric base like nylon or glass fiber, followed by reinforcing layers of composite materials. These materials, which include carbon-fiber acrylonitrile butadiene styrene (ABS) or thermoset resins, bond at the molecular level to create a truly integrated component that can transition from a flat panel into a complex 3D shape.

This mold-free approach addresses significant bottlenecks in traditional composite manufacturing, which often suffers from high mold costs and long lead times. By eliminating the need for molds, the ORNL team demonstrated a 95 percent reduction in fabrication time and a 90 percent reduction in costs for printing unique designs compared to conventional methods. Furthermore, the technique enables the fabrication of objects larger than the 3D printing machine itself, effectively bypassing capital cost limitations and storage challenges associated with traditional tooling.

The research team, which includes Ahmed Arabi Hassen, Katie Copenhaver, and others from ORNL’s Manufacturing Science Division, has filed a patent for the technology and is currently preparing it for future licensing. The project is supported by the Department of Energy’s Advanced Materials and Manufacturing Technologies Office, aiming to catalyze the transformation of U.S. manufacturing. By broadening access to mold-free hybrid composites, the innovation empowers manufacturers to explore new design possibilities and unlock applications for large-scale, robust structural components.