Synthesis of shape morphing compliant mechanisms based on the curved beam load path method

Compliant mechanisms (CMs), which utilize material elasticity to transmit motion, forces, and energy, present a lightweight, low-maintenance, and precise alternative to traditional rigid mechanisms. However, designing high-precision shape morphing CMs is challenging. Traditional Load Path Method typically use straight beam elements and struggle to control path intersections effectively, leading to limited morphing ranges, high stress, and complex structures reliant on 3D printing. This study proposes the Curved Beam Load Path Method, which integrates curved beam elements to expand the design flexibility and employs an optimized path generation strategy with two-level connections and collision detection algorithms to prevent path intersections. Applied to sector-shaped CMs and variable camber wing trailing edges, this method not only simplifies structures but also significantly reduces stress levels (by 25.7 % and 31.6 %, respectively) and maintains high-precision deformation control (with an average error of 1.85 %). These findings affirm the efficacy of the Curved Beam Load Path Method in reducing stress, streamlining structure, and enhancing manufacturability, thereby confirming its practicality and superiority in the design of shape morphing compliant mechanisms.