Origami-engineered tubes weigh 2 lbs, hold 165 pounds, fold flat for easy use

A new tubular structural system designed by engineers from RMIT University might revolutionize the construction and engineering worlds.

This new design can be folded flat when not in use and can be easily transported, and once unfolded, it becomes a strong locking structure.

The insight is based on the art of curved-crease origami, in which compact shapes are assembled into greater structures through geometric transformations.

This new system is practically applicable in a broad spectrum ranging from civil construction to aerospace, with positive signs for both gigantic and specific construction project types.

One advantage of the design is that the tubes lock into place, adding sturdiness without the assistance of other gear or human intervention.

Origami-inspired innovation

The tubular system, led by Dr. Jeff (Ting-Uei) Lee and Distinguished Professor Mike (Yi Min) Xie, is inspired by bamboo, a natural material with internal structures that provide excellent reinforcement. The engineering team replicated this feature through intelligent geometric design.

“This self-locking system is the result of an intelligent geometric design,” said Dr. Lee, from RMIT’s School of Engineering.

The key to the system lies in curved-crease origami . Unlike traditional paper folding, which uses straight crease lines, this technique uses curved lines to create strength and stability.

This approach allows the tubes to lock into place and support substantial weight. For instance, a panel made from multiple tubes, weighing just 2.8 pounds (1.3 kg), can support a person weighing 165 pounds (75 kg).

The flat-pack design is already common in various fields, including biomedical devices, robotics, aerospace, and disaster recovery efforts. However, the new system developed by RMIT engineers makes the assembly of these tubes quicker and more efficient while also enhancing their strength.

“Our invention is suitable for large-scale use,” added Dr. Lee, explaining that the tubular design has the potential for widespread applications.

Applications in space and beyond

The research team also sees potential for their flat-pack tubes in space missions . Dr. Lee highlighted that NASA already uses tubes packed flat, such as those in solar arrays that are unfurled in space. However, the existing tubes are hollow and could deform under certain forces.

“With our new design, these booms could be a stronger structure,” Lee said.

This is just one example of how the RMIT team’s innovation could improve current deployable systems, which rely on lightweight, easy-to-transport materials. The team believes their research opens up new possibilities for multifunctional designs.

“When NASA deploys solar arrays, for example, the booms used are tubes that were packed flat before being unfurled in space,” Lee noted. “Our new tubes, inspired by origami principles, could offer increased structural strength under various conditions.”

Dr. Xie emphasized the adaptability of the new system, pointing out that their smart algorithm allows for controlling how the tubes behave under different forces. By changing the orientation of the tubes, engineers can tailor the structure’s strength and flexibility.

“With our origami-inspired innovation , flat-pack tubes are not only easy to transport, but they also become strong enough to withstand external forces when in use,” Xie said. “The tube is also self-locking, meaning its strong shape is securely locked in place without the need for extra mechanisms or human intervention.”

Future directions and advancements

The research is the result of a collaboration between RMIT University’s School of Engineering and the University of Queensland. The team, which includes Drs. Hongjia Lu, Jiaming Ma, Ngoc San Ha, and Associate Professor Joseph Gattas plan to take the design even further.

One of the next steps in the research is to extend the self-locking feature to different tube shapes. The team is also keen to see how the tubes perform under a variety of forces, such as bending, twisting, and other mechanical stresses.

“We aim to extend the self-locking feature to different tube shapes and test how the tubes perform under various forces, such as bending and twisting,” Dr. Lee explained in the press release.

In addition, the team is exploring new materials and manufacturing methods to create even smaller and more precise tubes. The goal is to develop a range of tubes that can deploy themselves with minimal manual effort, making them even more versatile in real-world applications.

“We plan to improve our smart algorithm to make the tubes even more adaptable and efficient for different real-world situations,” Xie said .

This innovation is a significant leap forward for deployable structures and has the potential to reshape how engineers approach everything from space exploration to emergency construction.

RMIT team’s work continues to push the boundaries of structural design, offering a glimpse into a future where compact, self-deploying systems play a key role in engineering.

The research is detailed in the journal PNAS .