Oak Ridge National Laboratory (ORNL) has demonstrated a new additive manufacturing approach that integrates origami-inspired design principles with hybrid composite materials, enabling the creation of complex, shape-transforming structures that are difficult or impossible to achieve using conventional manufacturing methods.
ORNL researcher Steven Guzorek, who leads the project, said this pioneering method redefines advanced manufacturing by fusing material science with transformative design principles. By applying origami-inspired principles to hybrid composites, the team is improving the efficiency and scalability of large-structure manufacturing and achieving forms unattainable with traditional additive approaches, advancing robust, cost-effective solutions for a broad range of applications.
The research team emphasized that material selection played a critical role in achieving structural performance and integration. Guzorek noted that by understanding the materials science, the team chose materials known to bond effectively, producing a truly integrated component.
The approach focuses on combining multiple materials into a unified structure while leveraging geometrical folding concepts inspired by origami. This enables engineered components that can transition between configurations while maintaining strength and functionality.
A key objective of the work is scalability, with researchers aiming to extend the method beyond laboratory demonstrations. Guzorek said the goal is to make this innovation scalable so manufacturers across industries can harness its potential, broadening access to mold-free hybrid composites and empowering manufacturers to explore new design possibilities.
The development aligns with broader trends in advanced manufacturing, where additive techniques are increasingly being used not just for part production, but for creating architected materials with programmable mechanical behavior.
Source: ORNL | News
