In a remarkable leap forward blending the intricacies of origami, kirigami, and advanced materials engineering, a newly published study unveils pioneering structures that could redefine architectural and mechanical design principles. Authored by Zhao, Cui, Zou, and their colleagues, the research introduces one-degree-of-freedom flat-foldable thick-panel origami-kirigami constructs, demonstrating modular arrays and closed polyhedral geometries. Their work, appearing in Communications Engineering in 2025, bridges the gap between traditional paper-folding art forms and the demands of real-world engineering applications requiring rigidity, scalability, and deployability.
The essence of this innovation lies in overcoming the limitations imposed by thickness in foldable panels. Historically, origami-inspired designs have been constrained primarily to thin, flexible sheets, which limited practical usage in engineered structures where material thickness and robustness are indispensable. The introduction of thick-panel systems capable of flat-folding using a single degree of freedom represents a monumental shift. It not only enhances mechanical reliability but also enables a new horizon of modularity and complexity in three-dimensional structures.
Flat-foldability traditionally demands that a structure can be completely compressed into a two-dimensional form without damaging the material or losing structural integrity. Achieving this with thick panels has long posed a formidable challenge because thickness introduces geometric and mechanical constraints that conflict with folding mechanisms. The authors deftly circumvent these challenges by integrating kirigami principles—strategic cutting patterns complementing folding motions—to relieve stress concentrations and enable smooth transitions between folded and unfolded states.
This marriage of origami’s folding artistry with kirigami’s cutting strategies provides the framework for one-degree-of-freedom actuation, a highly desirable feature that simplifies mechanical control. Essentially, this means the entire complex folding and deployment process can be governed by a single input motion—such as a hinge rotation or linear actuator. This simplicity paves the way for practical applications where automated or remote folding is necessary, particularly in aerospace, deployable shelters, and soft robotics where compact stowage and reliable deployment are critical.
One of the study’s striking highlights is the successful creation of modular arrays composed of these thick-panel units. Modular arrays open vast potential in scalable engineered systems; they allow for repeated assembly of identical units to achieve large-area structures with predictable mechanical properties. This modularity, combined with flat-foldability, means large-scale deployable architectures can be compressed for transport and rapidly expanded on-site, a characteristic invaluable for disaster relief, temporary constructions, or space habitats.
Furthermore, the research delves deeply into the geometric foundations enabling such foldable thick-panel structures. Utilizing rigorous mathematical modeling and kinematic analyses, the authors elucidate the precise conditions under which these panels can fold flat without interference. This theoretical framework extends classical origami mathematics into three-dimensional panel thickness realms and accounts for material deformation, hinge design, and cutting pattern layouts—an interdisciplinary synthesis involving computational geometry, mechanical engineering, and materials science.
Closed polyhedra constructed from these thick-panel origami-kirigami units demonstrate not only aesthetic elegance but also structural strength and dynamic reconfigurability. Closed polyhedra are airtight, three-dimensional shapes that can encapsulate volume, making them prospective candidates for containers, adaptive enclosures, or robotics chassis. The paper showcases how these closed forms maintain their mechanical integrity through the folding cycles, a vital factor for reusable engineering components subjected to repeated deformation.
The practical implications of this research ripple across numerous industries. For instance, in aerospace engineering, where payload volume and weight constraints are stringent, deployable thick-panel origami structures can allow satellite components or solar arrays to be compactly stowed during launch and then reliably deployed in orbit. Similarly, in civil engineering, modular flat-foldable thick panels could revolutionize temporary or mobile infrastructure, providing rapid-deploy shelters or barriers that are sturdy yet lightweight and easy to transport.
A key aspect of the work involves materials selection and hinge mechanics. Thick panels inherently resist bending, making conventional crease patterns impractical. The authors address this by engineering discrete hinges—composite joints that allow rotation while bearing loads—and integrating these into the panel design with precision. This hybrid approach leverages modern manufacturing techniques such as laser cutting and additive manufacturing, underscoring the research’s relevance at the convergence of design theory and fabrication technology.
Moreover, the study’s findings open horizons in the field of soft robotics, where flexibility, adaptability, and compactness are prized. With controlled folding enabled by one-degree-of-freedom actuation, robotic structures inspired by these origami-kirigami principles can transform shape, navigate constrained spaces, or alter stiffness dynamically. This adaptability has profound implications for medical devices, search and rescue robots, or any system requiring versatile mechanical morphology.
The authors also explore the scalability of their designs, providing insight into how the folding mechanisms and structural behaviors persist or evolve when the panel size or the array dimensions change. Such scalability analysis is crucial when transitioning prototypes to real-world applications, ensuring that mechanical advantages are preserved from small to large constructs, and that manufacturing tolerances can be managed effectively.
In addition, the research introduces novel computational tools and simulation methods crafted to model thick-panel origami-kirigami folding pathways accurately. These tools enable designers to visualize folding sequences, assess mechanical stresses, and optimize hinge placement and cut patterns before physical prototyping, saving costs and accelerating innovation cycles. The integration of simulation and experimental validation embodies a comprehensive methodology that sets a new standard in the development of foldable engineered systems.
Ethical and environmental considerations also emerge indirectly from this advancement. Deployable modular arrays designed with durable thick materials can reduce the waste and energy consumption associated with temporary constructions. Their reusability and ease of transport confer sustainability advantages, aligning with global efforts to minimize the environmental impact of human-made structures. This research, therefore, resonates beyond engineering, contributing to responsible design practices.
Overall, the combination of theoretical innovation, experimental demonstration, and practical foresight marks this study as a seminal contribution to the field of foldable structures. The clarity in uniting thick-panel mechanics with one-degree-of-freedom motion, alongside the successful realization of functional modular arrays and closed polyhedra, not only advances academic understanding but also lays groundwork for future technologies. This work exemplifies how age-old arts like origami and kirigami can be reimagined through modern science to solve contemporary engineering challenges.
Looking ahead, the potential to integrate smart materials, such as shape-memory alloys or responsive polymers, with these thick-panel origami-kirigami systems offers tantalizing prospects. Active materials could imbue these structures with autonomous folding and unfolding capabilities, triggered by environmental stimuli or programmed control sequences. Such advancements would transcend mechanical simplicity, delivering intelligent reconfigurable systems adaptable to a variety of dynamic environments.
In sum, this pioneering research embodies a fusion of art, science, and engineering, heralding a new era where foldable thick-panel origami-kirigami architectures offer transformative solutions across myriad fields. Its implications resonate from the micro-scale of robotic components to the macro-scale of deployable buildings and spacecraft, inviting a reexamination of how we design, build, and interact with the physical world.
Subject of Research: One-degree-of-freedom flat-foldable thick-panel origami-kirigami structures, focusing on modular arrays and closed polyhedra.
Article Title: One-degree-of-freedom flat-foldable thick-panel origami-kirigami structures: modular arrays and closed polyhedra.
Article References:
Zhao, C., Cui, E., Zou, S. et al. One-degree-of-freedom flat-foldable thick-panel origami-kirigami structures: modular arrays and closed polyhedra. Commun Eng 4, 62 (2025). https://doi.org/10.1038/s44172-025-00397-3
Image Credits: AI Generated
