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Abstract A new class of thin flexible structures is introduced that morph from flat into prescribed 3D shapes through strain mismatch between layers of a composite plate. To achieve control over the target shape, two different concepts are coupled. First, motivated by biological growth, strain mismatch is applied between the flat composite layers to transform it into a 3D shape. Depending on the amount of the applied strain mismatch, the transformation involves buckling into one of the available finite number of deformation modes. Second, inspired by kirigami, portions of the material are removed from one of the layers according to a specific pattern. This dramatically increases the number of possible 3D shapes and allows us to attain specific topologies. An experimental apparatus that allows precise control of the strain mismatch is devised. An inverse problem is posed, where starting from a given target shape, the physical parameters that make these shapes possible are determined. To show how the concept works, it focuses on circular composite plates and designs a kirigami pattern that yields a hemispherical structure. The analysis combines a theoretical approach with numerical simulations and physical experiments to understand and predict the shape transition from 2D to 3D. The tools developed here can be extended to attain arbitrary 3D shapes. The initially flat shape suggests that conventional additive manufacturing techniques can be used to functionalize the soft kirigami composite to fabricate, for example, deployable 3D structures, smart skins, and soft electromagnetic metasurfaces. 

Abstract High performance thermal insulation materials are desired for a wide range of applications in space, buildings, energy, and environments. Here, a facile ambient processing approach is reported to synthesize a highly insulating and flexible monolithic poly(vinyl chloride) aerogel. The thermal conductivity is measured respectively as 28 mW (m K)⁻¹at atmosphere approaching the air conductivity and 7.7 mW (m K)⁻¹under mild evacuation condition. Thermal modeling is performed to understand the thermal conductivity contributions from different heat transport pathways in air and solid. The analysis based on the Knudsen effect and scattering mean free paths shows that the thermal insulation performance can be further improved through the optimization of porous structures to confine the movement of air molecules. Additionally, the prepared aerogels show superhydrophobicity due to the highly porous structures, which enables new opportunities for surface engineering. Together, the study demonstrates an energy‐saving and scalable ambient‐processing pathway to achieve ultralight, flexible, and superhydrophobic poly(vinyl chloride) aerogel for thermal insulation applications.