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In this paper we propose a general method for creating a new type of hierarchical structures at any level in both 2D and 3D. A simple rule based on a rotate-and-mirror procedure is introduced to achieve multi-level hierarchies. These new hierarchical structures have remarkably few degrees of freedom compared to existing designs by other methods. More importantly, these structures exhibit synchronized motions during opening or closure, resulting in uniform and easily-controllable deformations. Furthermore, a simple analytical formula is found which can be used to avoid collision of units of the structure during the closing process. The novel design concept is verified by mathematical analyses, computational simulations and physical experiments.

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The need to simplify the construction issues of complex structures leads to definition of SmartNodes project as a research which aims to confine the complexity of structure to a limited area (nodes) in order to decrease processing steps and labor intensity by application of additive manufacturing (AM) techniques. Bi-Directional Evolutionary Structural Optimization (BESO) is used to design efficient and elegant nodal connections of large scale spatial structures and minimise the volume of nodes to be printed and to ultimately replace welded, forged and cast connections by 3D printed connections. The prototypes discussed in this paper demonstrate BESO design process through two generic cases.