A novel heterogeneous polyhedral mechanism for shape morphing application

Shape morphing mechanisms (SMMs) have attracted significant interest due to their adaptive shape-change capabilities and superior controllability, particularly in aerospace applications. However, most existing rigid-body SMMs consist of planar mechanisms, which inherently limit their deformation to two dimensions. Three-dimensional(3D) SMMs are generally derived from polyhedral truss structures, yet the design methodologies for this transformation remain underexplored. This article introduces an innovative design methodology that employs loop theory and split vertex technology to convert truss structures into kinematic mechanisms, resulting in a novel SMM. The proposed mechanism significantly enhances continuous shape morphing capabilities in higher dimensions than existing SMMs. Then, a kinematic model is established to analyze the relationship between the transformation modes and distributed actuation. Finally, a two-module prototype SMM is fabricated, and morphing experiments are conducted. The results show that the innovative mechanism can achieve shape extension, spanwise bending, chordwise sweeping, twisting, and verify the effectiveness of the shape morphing model. This mechanism holds promise for advancing the rigid–flexible coupled morphing designs in future aircraft.