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Mechanisms that can both deploy and perform desired tasks offer a multifunctional advantage over traditional mechanisms. Developable mechanisms (DMs) are devices capable of conforming to a predetermined developable surface and deploying from that surface to achieve specific motions. This paper presents new terminology that defines motion of developable mechanisms while interior and exterior to a developable surface. The limits of motion are identified using defined conditions, and it is shown that the more difficult of these conditions may be treated as a non-factor during the design of cylindrical developable mechanisms given certain assumptions.

 

We demonstrate analytically that it is possible to construct a developable mechanism on a cone that has rigid motion. We solve for the paths of rigid motion and analyze the properties of this motion. In particular, we provide an analytical method for predicting the behavior of the mechanism with respect to the conical surface. Moreover, we observe that the conical developable mechanisms specified in this paper have motion paths that necessarily contain bifurcation points which lead to an unbounded array of motion paths in the parameterization plane.

 

Cylindrical developable mechanisms are devices that conform to and emerge from a cylindrical surface. These mechanisms can be formed or cut from the cylinder wall itself. This paper presents a study on adapting traditional hinge options to achieve revolute motion in these mechanisms. A brief overview of options is given, including classical pin hinges, small-length flexural pivots, initially curved beams, and an adaptation of the membrane thickness-accommodation technique. Curved Lamina Emergent Torsional (LET) joints are then evaluated in detail, and a thin-walled modeling assumption is checked analytically and empirically. A small-scale cylindrical developable mechanism is then evaluated with Nitinol curved LET joints.

 

This paper presents tools and methods to design cylindrical and conical developable mechanisms from flat, planar patterns. Equations are presented that relate the link lengths and link angles of planar and spherical mechanisms to the dimensions in a flat configuration. These flat patterns can then be formed into curved, developable mechanisms. Guidelines are established to determine if a mechanism described by a flat pattern can exhibit intramobile or extramobile behavior. A developable mechanism can only potentially exhibit intramobile or extramobile behavior if none of the links extend beyond half of the flat pattern. The behavior of a mechanism can change depending on the location of the cut of the flat pattern. Different joint designs are discussed including lamina emergent torsional (LET) joints. Physical examples are presented.

 

The ability to deploy a planar surface to a desired convex profile can enhance foldable or morphing airfoils, deployable antennae and reflectors, and other applications where a specific profile geometry is desired from a planar sheet. A model using a system of rigid links joined by torsional springs of tailorable stiffness is employed to create an approximate curved surface when two opposing tip loads are applied. The physical implementation of the model uses compliant torsion bars as the torsion springs. A multidimensional optimization algorithm is presented to minimize the error from the rigid-link approximation and account for additional manufacturing and stress considerations in the torsion bars. A proof is presented to show that equal torsion spring spacing along the horizontal axis of deployed parabolic profiles will result in minimizing the area between the model’s rigid-link approximation and smooth curve. The model is demonstrated through the physical construction of a deployable airfoil surface and a metallic deployable parabolic reflector.

 

Developable mechanisms conform to and emerge from developable, or specially curved, surfaces. The cylindrical developable mechanism can have applications in many industries due to the popularity of cylindrical or tube-based devices. Laparoscopic surgical devices in particular are widely composed of instruments attached at the proximal end of a cylindrical shaft. In this paper, properties of cylindrical developable mechanisms are discussed, including their behaviors, characteristics, and potential functions. One method for designing cylindrical developable mechanisms is discussed. Two example developable surgical devices that exemplify these behaviors, characteristics, and functions, along with the kinematic mechanisms comprising them, are discussed in detail.

 

In many origami-based applications a device needs to be maintained in one or more fold states. The origami stability integration method (OSIM) presented in this paper provides an approach for graphically combining various techniques to achieve stability. Techniques are divided into four groups based on whether they are intrinsic or extrinsic to the origami pattern and whether they exhibit differentiable or non-differentiable energy storage behaviors. These categorizations can help designers select appropriate techniques for their application. The paper also contains design considerations and resources for several intrinsic techniques. Finally, two case studies are presented which use the OSIM and the technique guidelines to conceptualize stability in origami-based devices.

 

Stopping origami in arbitrary fold states can present a challenge for origami-based design. In this paper two categories of kirigami-based models are presented for stopping the fold motion of individual creases using deployable hard stops. These models are transcrease (across a crease) and deploy from a flat sheet. The first category is planar and has behavior similar to a four-bar linkage. The second category is spherical and behaves like a degree-4 origami vertex. These models are based on the zero-thickness assumption of paper and can be applied to origami patterns made from thin materials, limiting the motion of the base origami pattern through self-interference within the original facets. Model parameters are based on a desired fold or dihedral angle, as well as facet dimensions. Examples show model benefits and limitations.

 

Origami concepts show promise for creating complex deployable systems. However, translating origami to thick (non-paper) materials introduces challenges, including that thick panels do not flex to facilitate folding and the chances for self-intersection of components increase. This work introduces methods for creating permutations of linkage-based, origami-inspired mechanisms that retain desired kinematics but avoid self-intersection and enable their connection into deployable networks. Methods for reconfiguring overconstrained linkages and implementing them as modified origami-inspired mechanisms are proved and demonstrated for multiple linkage examples. Equations are derived describing the folding behavior of these implementations. An approach for designing networks of linkage-based origami vertices is demonstrated and applications for tessellations are described. The results offer the opportunity to exploit origami principles to create deployable systems not previously feasible.

 

Abstract We present a resource for designing bistable developable mechanisms (BDMs) that reach their second stable positions while exterior or interior to a cylindrical surface. Analysis of the necessary conditions to create extramobile and intramobile cylindrical BDMs is conducted through a series of three tests. These tests contain elements of both existing and new mechanism design tools, including a novel graphical method for identifying stable positions of linkages using a single dominant torsional spring, called the principle of reflection. These tests are applied to all possible mechanism cases and configurations to identify why certain configurations will always, sometimes, or never be a BDM. Two tables summarize these results as a guide when designing extramobile and intramobile BDMs. The results are compared and demonstrated with a numerical simulation of 30,000+ mechanisms, including several example mechanisms that illustrate the concepts discussed in the work. Discussion is then provided on the implication of these results.