4D-Printed “Ori-Lattice” With Ultrahigh Foldability and Load-Bearing Capacity

Origami-inspired structures offer remarkable foldability but often lack the load-bearing capacity required for engineering applications. To address this challenge, this study introduces the ‘Ori-lattice’, a novel structural concept that synergistically integrates the kinematic versatility of origami with the mechanical robustness of cellular lattice structures. The design features a lightweight lattice core sandwiched between two origami panels, which is fabricated as a monolithic unit using 4D printing. A key contribution of this work is a comprehensive design framework with geometric and parametric derivations that resolves mechanical interference during folding, enabling the coupling of various origami patterns with compatible lattices. Leveraging shape memory polymers, the resulting Ori-lattice structures can be thermally actuated to autonomously deploy from a compact, folded state to a stable unfolded, load-bearing configuration. Experimental and computational analyses validate that the Ori-lattice design successfully achieves both a high depolyment ratio for compact stowage and exceptional compressive and flexural strength for in-service performance. By eliminating the need for traditional hinges or external assembly, the Ori-lattice concept provides a new paradigm for creating lightweight, deployable, and resilient systems, paving the way for the next generation of multifunctional structures with broad applications in aerospace, robotics, and architecture.