Multiplanar manufacturing: A new approach to design for manufacturing and assembly of origami

Abstract

This paper explores multiplanar manufacturing as an alternative approach for fabricating three-dimensional origami-inspired devices. Traditional origami manufacturing techniques typically employ a monoplanar method, which confines origami to a single plane, during manufacturing, and limits their design efficiency. By contrast, multiplanar manufacturing fabricates panels and hinges across multiple planes, offering greater design flexibility and the potential to eliminate some assembly/bonding operations. This study demonstrates the impact of multiplanar manufacturing on material usage, build footprint, and actuation requirements. For the geometries used as a case study, the benefits of multiplanar manufacturing include reducing material usage by up to 62%, actuation steps by up to 93%, and build footprint by up to 91%—relative to a monoplanar configuration in the geometries studied. These benefits improve efficiency, streamline assembly processes, and enable new avenues for fabricating origami-inspired devices. The findings position multiplanar manufacturing as a promising strategy for efficiently producing three-dimensional origami-inspired structures, paving the way for advancements in various engineering fields.