In this paper we develop techniques for designing stable flat-foldable wooden furniture. Thickness-accommodation techniques used to enable folding of origami from thick materials are shown to also be applicable to wood. Specifically, wood may be used in (and is stable in) the unique load-bearing conditions of vertical lamina emergent torsional (LET) joints and arrays and angled-from-vertical modified origami tessellations, which utilize membrane joints to accommodate thickness. We present and analyze data for LET arrays of various heights in compression. In addition to being unique in load-bearing conditions, the presented structures are unique in that they are collapsible and deployable and fold from their deployed state to a completely flat state. The viability of using LET arrays as load-supporting joints — both in vertical and horizontal orientations — is also discussed. We present a design for a deployable stool and chair which gain their movement from carefully-placed LET joints and may be manufactured with a CNC mill from a single sheet of plywood. A design for a deployable chair based on an origami tessellation is also presented, which consists of six wooden panels cut on a CNC mill, and has a comparatively small surface area in its flat-folded state and may thus be more easily transported.
Small-scale flexible (or compliant) mechanisms are valuable in replacing rigid components while retaining comparable motion and behavior. However, fabricating such mechanisms on this scale (from 0.01 to 10 cm) proves difficult, especially with thin sheet metals. The manufacturing method of laser forming, which uses a laser to cut and bend metal into desired shapes, could facilitate this fabrication. However, specific methods for designing mechanisms formed by lasers need to be developed. This work presents laser forming as a means for creating compliant mechanisms on this scale with thin sheet metal. The unique challenges for designing mechanisms to be laser formed are explored, and new adaptations of existing designs are fabricated and discussed. The design of basic “building-block” features is developed for several mechanisms: a parallel-guided mechanism, a cross-axis flexural pivot, a lamina emergent torsional (LET) joint array, a split-tube flexure, and a bi-stable switch. These mechanisms are shown to perform repeatable behavior and motion comparable to existing nonlaser-formed versions. The further possibilities for fabricating compliant mechanisms with laser forming are explored, as advanced applications can benefit from using lasers to create compliant mechanisms from thin sheet metal.
Design projects in childcare settings present unique design challenges because of their function, size, and specific safety concerns. In selecting effective childcare furniture, stowage space, safety, and ease of access for childcare furniture are important considerations. Origami-inspired design can be useful in addressing these issues in an innovative way by introducing flat-foldability and deployability into childcare furniture. Fundamental design considerations for childcare furniture and mechanical design principles for deployable furniture are examined in order to understand how to make safe and functional furniture pieces. Childcare furniture must be very child-safe. This means that origami principles used must not add safety concerns like decreased stability or pinch points. Nonhazardous, durable, and comfortable materials must be used. Extra precaution must be taken when designing folding structures for use in a childcare environment. Mechanical principles for such systems, including folding methods and thickness accommodation, are examined in the context of childcare spaces. Various types of joints are also examined and the M-LET compliant joint is shown as a potential replacement for rigid hinges in folding furniture. Using this understanding, this work presents two simple flat-folding techniques and a compliant joint suitable for a childcare setting and demonstrates these principles through functional “safe space” furniture.
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