OrigaMatic: A Computational Workflow for Multi-Material Design Bridging Thick-Panel Origami and Additive Manufacturing

Abstract Origami-based compliant mechanisms have unlocked new possibilities in the design of adaptable structures, resulting in lightweight, reconfigurable, and material-efficient systems. However, translating the complex 3D geometries needed for practical robotic applications into fabrication-ready 2D crease patterns remains a significant challenge. The need to accurately preserve kinematic behavior while ensuring flat-manufacturability introduces additional complexity in the design process. The fabrication of origami through multimaterial extrusion additive manufacturing (MME-AM) offers a compelling solution by integrating rigid and flexible materials in a single print. Still, in turn, it poses difficulties due to the complexities related to pattern generation, its intricate assembly, unfolding, and folding sequences. To address these challenges, this work introduces OrigaMatic, a parametric computational algorithm that converts zero-thickness kinetic origami models into fabrication-ready, 3D-printable flat layouts. These developed structures can be further re-folded into their intended 3D configurations, ensuring both kinematic accuracy and structural integrity. By automating this process, the workflow accelerates the transition from concept to fabrication. It eliminates the need for manual intervention in unfolding complex mechanisms, reducing time in the design-to-fabrication process while enhancing reproducibility. The effectiveness of OrigaMatic is demonstrated by experimental validation through the fabrication of compliant prototypes, with a focus on parallel mechanisms relevant to the fields of small-scale machinery and robotics. The investigation highlights the ability of the algorithm to streamline the origami-inspired mechanism design while preserving structural integrity and kinematic functionality.