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Research Papers

Manufacture of Arbitrary Cross-Section Composite Honeycomb Cores Based on Origami Techniques

[+] Author and Article Information
Kazuya Saito

Department of Mechanical and
Biofunctional Systems,
Institute of Industrial Science,
The University of Tokyo,
4-6-1 Komaba,
Tokyo 153-8505, Japan
e-mail: saito-k@iis.u-tokyo.ac.jp

Sergio Pellegrino

California Institute of Technology,
Pasadena, CA 91125
e-mail: sergiop@caltech.edu

Taketoshi Nojima

Art Excel Co., Ltd,
Hirakata, Osaka 573-1112, Japan
e-mail: taketoshinojima@gmail.com

1Corresponding author.

Contributed by the Design Automation Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received September 18, 2013; final manuscript received February 6, 2014; published online March 25, 2014. Assoc. Editor: Shinji Nishiwaki.

J. Mech. Des 136(5), 051011 (Mar 25, 2014) (9 pages) Paper No: MD-13-1413; doi: 10.1115/1.4026824 History: Received September 18, 2013; Revised February 06, 2014

As observed in the design of antenna reflectors and rocket bodies, both flat and 3D-shaped honeycomb cores are used in the field of aerospace engineering. This study illustrates a new strategy to fabricate arbitrary cross-section honeycombs with applications of advanced composite materials by using the concept of the kirigami honeycomb, which is made from single flat sheets and has periodical slits resembling origami. The authors also describe a method of applying this technique to advanced composite materials. Applying the partially soft composite techniques, 3D shaped composite honeycombs are manufactured, and some typical samples are shown with their folding line diagrams.

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Figures

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Fig. 1

Concept of kirigami honeycomb core. (a) Basic folding lines diagram. Thick lines: Slits. Fine lines: mountain folding lines. Dashed lines: valley folding lines. (b)–(d) The folding process for realizing a honeycomb shape. The relation between FLD-axes (l, w) and core-axes (L, W, Z) is defined as this figure. L and W directions are correspond with the core ribbon direction and the mechanical (expanding) direction in normal honeycombs.

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Fig. 2

Examples of 3D folded honeycombs and their FLDs. Upper: tapered honeycomb. Lower: convex curved honeycomb. Black lines and areas: slits or cutouts. Gray lines: folding lines.

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Fig. 3

One directional modified cross-section honeycomb. The core thickness and curvature change only in the W direction. All cell walls are perpendicular to the LW surface, and each cell has a regular hexagonal cross-section.

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Fig. 4

Definition of the FLD parameters ai and bi. l and w-axes are defined based on Fig. 1

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Fig. 5

Definition of the cross-section parameters ti and ui

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Fig. 6

Types of unit cells and their slit shapes. (a) Flat cell with straight slits. (b) Tapered cell with zero width slit. (c) Convex curved cell with positive width slit. (Hexagon EDCBHG is a cutout area.) (d) Nonconvex curved cell with negative width cell. (Hexagon EDCBHG is an overlapping area.)

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Fig. 7

Approximated cross sections. (a) Partitioning with C/2 (previous methods), (b) partitioning with C (Proposed method to modify the unfoldable case)

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Fig. 8

Honeycomb core with parabolic surface (y = 0.002 x2 0.2x + 20) and sine curved surface (y = 10 sin(2πx/200)). (a) Cross section, (b) paper sample (C = 20 mm, 100 × 200 mm), and (c) FLD.

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Fig. 9

The concept of the mask printing method

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Fig. 10

Composite origami crane (a) mask created from unfolded crease pattern of origami crane, (b) the partially soft composite sheets with the crane pattern, (c) fold the sheets according to the folding process, and (d) the folded shape.

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Fig. 11

Samples of the masks. (a) Tapered honeycomb and (b) flat honeycomb

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Fig. 12

The mold is made from 450 mm length aluminum rods (c= 14.3 mm (9/16 in.), h= 7.15 mm, and a= 8.25 mm)

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Fig. 13

Schematic illustration of the lay-up

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Fig. 14

Cured CFRP sheets

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Fig. 15

Corrugated CFRP sheet with slits and folding lines and (b) its folding process

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Fig. 16

Samples of CFRP 3D honeycomb cores and their mask patterns. (a) Tapered core (C = 14.3 mm), (b) curved core (C = 14.3 mm), and (c) aerofoil (C = 14.3 mm).

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Fig. 17

Cross sections of the honeycomb shown in Fig. 8. (a) trace the cross-section, (b) discretization to dot sequence T, U, and (c) modification methods

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Fig. 18

Drawing FLD from ai and bi

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