Design and Analysis of a Hinge Splitting Method for Thick Flat Foldable Origami Tessellations

Abstract

Abstract. Origami-inspired engineering designs encounter a fundamental issue of non-negligible material thickness, which introduces structural interference during the development processes. To address this issue, this study builds upon the established hinge-splitting methods and proposes a novel methodology that splits hinges into pairs of mechanical joints and incorporates supplementary panels to connect adjacent main panels. Unlike membrane or flexible joints, the use of mechanical joints enhances motion accuracy and extends the operational lifespan of the mechanism, broadening its potential for engineering applications. First, we present a detailed methodology for structural design, providing a comprehensive solution for interference avoidance. Second, we define and analyze the kinematics of a thickened degree-4 vertex unit (TD4V), identify the structural interference arising from the double-hinge method, and propose a tailored structural design to resolve this issue. Finally, we introduce an algorithm for implementing a width-adding technique to split hinges in origami tessellations, supported by case studies that illustrate the algorithm's effectiveness. Our work advances the practical application of origami-inspired structures in fields such as aerospace, architecture, and robotics.