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

Abstract

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.