A conceptual design and structural analysis of thick panel kirigami for deployable volumetric modular structure

This study addresses key challenges in modular construction, such as transportation and lifting limitations, by introducing a kirigami-inspired modular structure that folds into a compact flat-pack and deploys into a volumetric form. The research explores two pop-up kirigami kinematic (i.e.V-fold and sliding) mechanisms utilising thick panel material for modular structural elements. The study develops spatial linkage with degree-four vertices by implementing a thick panel axis-shift method, enabling transformation into volumetric forms through a single-degree-of-freedom actuation. The structural performance of the kirigami deployment pattern under service loads was evaluated using finite element modelling. Fibre-reinforced polymer was selected as the primary material due to its low self-weight and adequate structural properties, making it a viable alternative to conventional steel for deployable structures. Results demonstrated compliance with design standards for displacements, stresses, and global drift. Additionally, the inclusion of a locking mechanism significantly enhances the structural stability of the module by restraining any potential movement in its fully deployed state. • Overview of pop-up kirigami with V-fold and sliding mechanisms. • The parameters of the thick panel kirigami models are presented. • Out-of-plane planar kinematics in thick panel kirigami are proposed. • Conceptual design of kirigami in deployable modular structure is proposed. • Modular structure’s practicality and structural analysis are presented.