Design and modeling of a programmable morphing structure with variable stiffness capability

The development of structures capable of both dynamic shape morphing and stiffness modulation has significant potential in various applications. However, such structures often suffer from bulkiness and control complexity. This paper addresses these challenges by exploring a scaled structure that integrates morphing capabilities and variable stiffness within a compact configuration. For the first time, we establish a comprehensive set of design criteria and obtain the previously unexplored design space, focusing on geometric parameters including layer thickness, target shape radius, the number of scales, and the number of periods per scale. Through extensive finite element simulations, we evaluate the impact of material property and geometric parameters on the performance of the scaled structure, emphasizing the role of coefficient of friction. Our findings identify a critical threshold for the coefficient of friction above which morphing ability is hindered. Additionally, we uncover a trade-off between morphing capability and stiffness variation ability, which we overcome by modifying the surface structure of the scales. The optimal design is found to be a superellipse shape with an exponent of ∼1.9. The practical potential of this structure is demonstrated through three applications: a soft gripper, a phone stand, and a foldable box, showcasing its versatility in real-world scenarios. This research provides a foundational approach for designing morphing scaled structures, offering valuable insights into optimizing morphing capability and stiffness variation ability for broader engineering applications.