Kirigami/Origami for Functional 3D Structures from Sheet Metal

19.02.2026, Diplomarbeiten, Bachelor- und Masterarbeiten

The goal is to develop a software-based generator that uses kirigami and origami principles to parametrically create diverse, functional, and manufacturable 3D structures from sheet metal. These structures will first be evaluated virtually against predefined functions and subsequently validated using physically manufactured demonstrators.

Background and Motivation

Principles of kirigami and origami enable the creation of novel three-dimensional structures from planar geometries through targeted cutting and folding. In sheet metal forming, such approaches offer potential for lightweight, stiff, energy-absorbing, or flexibly tunable structural elements—for example, in lightweight construction, damping, gripping and clamping structures, or function-integrated surfaces. However, the systematic design of such structures is challenging because manufacturability constraints (e.g., minimum ligament widths, radii, cut spacing, fold angles, and tool accessibility) and performance targets (e.g., stiffness, stretchability, mass, Poisson’s ratio, and local stress concentrations) must be considered simultaneously.

Objective of the Project

The aim of this study project is to develop a generator (a software-based design tool) that produces diverse yet manufacturable 3D sheet metal structures from parameterizable kirigami/origami patterns and automatically evaluates them against predefined properties. The investigation will first be carried out virtually (simulation/analysis); selected structures may then be manufactured and experimentally characterized.

Tasks / Scope

1. Literature Review & Requirements Definition
- Overview of kirigami/origami patterns and their transferability to sheet metal
- Derivation of manufacturability rules (cut/fold limits, radii, ligament widths, minimum spacing, tolerances)
- Definition of evaluation criteria/properties (e.g., stiffness, energy absorption, spring characteristic, mass, maximum stress, deflection, anisotropy)

2. Development of a Structure Generator
- Parametric description of suitable patterns (e.g., Miura-ori variants, slit patterns, tessellations)
- Algorithmic generation of 2D cut/fold patterns and derived 3D configurations
- Ensuring manufacturability via rules/constraints

3. Virtual Evaluation (Simulation/Analysis)
- Automated test pipeline for generated variants
- Determination of structural metrics per variant (e.g., FEM-based evaluation or simplified models)
- Comparison and selection of promising candidates using a scoring/optimization scheme

4. Physical Implementation & Validation
- Selection of representative structures
- Manufacturing (e.g., laser cutting/waterjet + bending/folding)
- Experimental characterization (e.g., compression/tension testing, bending tests, force–displacement curves)

5. Comparison of Simulation vs. Experiment, discussion of deviations and underlying causes

Prerequisites / Profile

- Interest in generative design, lightweight structures/structural mechanics, or sheet metal manufacturing
- Basic programming skills (e.g., Python/Matlab) are an advantage
- CAD/FEM experience is helpful

Kontakt: christoph.hartmann@tum.de