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In this paper, we present a Modular Origami Approach for Rigid Foldable Steel Load-Bearing Plate Lattices in Arbitrary Sizes.

While plate lattices exhibit superior mechanical performance compared to truss lattices at equivalent densities, their fabrication on an engineering scale presents significant challenges, particularly when utilizing structural materials for loadbearing applications. Industry and academia predominantly rely on 3D printing techniques, but encounter limitations in feature size and scalability of energy efficiency for high production rates. In this study, we propose a modular origami design and manufacturing method for creating steel plate lattices at the meso-scale
using sheet stock. Rigid-foldable unit cells are cut, folded, and discretely assembled into lattices. Their mechanical performance is simulated and mechanically tested.

This paper introduces a simple and scalable manufacturing method for fabricating metallic plate lattices via progressive folding and modular assembly. In our study,
we employ stainless steel sheet stock with a thickness of 180 microns. The process of folding metallic sheets necessitates overcoming plastic deformation.
Creases, form local areas of high strain, which necessitates the selection of a material with high toughness with a high ultimate stress. However, the inherent trade-off between toughness and strength in materials requires a compromise. Martensitic steels are ideal for their strength, whereas austenitic steel
offers better formability. In this paper we use cold worked austenitic 301 stainless steel, as this material is widely available, recyclable and economically affordable.

The paper also covers the analytical way of geometry generation and simulation. Check the full paper and don’t hesitate to contact us!