Flexural Digital Material Lattice for Shape-Morphing Structures
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Solution Overview
Problem
Conventional materials and manufacturing methods for shape-morphing structures are limited by high density, high cost, and complexity, restricting size, degrees of freedom, and manufacturability, while composite and cellular materials face challenges in production, repair, and widespread use due to high costs and labor intensiveness.
Innovation Solution
The development of digital composites and digital cellular solids, which utilize discrete units assembled into lattice geometries to achieve scalable, flexible, and reversible structures with spatially distributed deformation, enabling efficient actuation and programmable movements through a global control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional kinematics with flexural components are used, then shape-morphing capability is achieved, but the structure density and cost increase significantly
Solution Approach 1:
The structure is divided into discrete modular units that can be independently controlled and assembled. Each unit contains flexural components that can be actuated independently, allowing shape-morphing without requiring the entire structure to be dense or continuous. This segmentation enables lightweight construction while maintaining adaptability.
Solution Approach 2:
The patent transitions from continuous analog materials to discrete digital materials, adding a dimensional aspect of discretization. By representing structures as assemblies of discrete units with specific geometries and connections, the system achieves shape-morphing through combinatorial arrangements rather than continuous material variation, reducing overall density requirements.
2Ease of operation
If high density materials such as piezoelectric ceramics and shape memory alloys are used, then actuation capability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the fundamental parameters of actuation by replacing high-density specialized materials with discrete geometric units that achieve actuation through their shape and connectivity. Instead of relying on material properties like piezoelectricity or shape memory effects, the system uses controlled deformation of discrete units with specific geometries, simplifying manufacturing while maintaining actuation capability.
Solution Approach 2:
The invention uses replicated discrete units with identical or similar geometries that can be manufactured using standard processes and then assembled into complex structures. This copying approach replaces the need for expensive, specialized high-density materials with simple, reproducible geometric elements, reducing manufacturing complexity and cost.
3Weight of moving object
If composite materials are used to reduce weight, then strength-to-weight ratio improves, but design and processing costs increase significantly
Solution Approach 1:
The composite structure is segmented into discrete units that can be manufactured separately using simple processes and then assembled. This segmentation avoids the need for complex continuous composite layup and curing processes, reducing design and processing costs while maintaining weight reduction benefits through optimized unit geometries and selective material placement.
Solution Approach 2:
The patent applies materials and structural features locally to discrete units based on their specific functional requirements, rather than using uniform composite construction throughout. This local quality approach allows simple materials and processes for most units while providing enhanced properties only where needed, reducing overall design and processing costs.
4Weight of moving object
If cellular materials are used, then lightweight properties are achieved, but production and repair become labor intensive
Solution Approach 1:
The cellular structure is segmented into discrete modular units that can be manufactured independently using automated processes. Each unit is a complete functional element that can be produced through simple replication rather than labor-intensive cellular structure fabrication, reducing production labor intensity while maintaining lightweight properties through the modular assembly architecture.
Solution Approach 2:
The patent uses replicated discrete units that can be manufactured through copying and assembly rather than labor-intensive cellular material fabrication. Standardized unit geometries enable automated manufacturing and simplification of repair processes, as damaged units can be replaced by copying good ones, reducing both production and repair labor intensity.
Data Source
AI summary
Flexural digital materials are discrete parts that can be assembled into a lattice structure to produce an actuatable structure capable of coordinated reversible spatially-distributed deformation. The structure comprises a set of discrete flexural digital material units assembled according to a lattice geometry, with a majority of the discrete units being connected, or adapted to be connected, to at least two other units according to the geometry. In response to certain types of loading of the structure, a coordinated reversible spatially-distributed deformation of at least part of the structure occurs. The deformation of the structure is due to the shape or material composition of the discrete units, the configuration of connections between the units, and/or the configuration of the lattice geometry. Exemplary types of such actuatable structures include airplane wing sections and robotic leg structures. An automated process may be employed for constructing an actuatable structure from flexural digital materials.