A team from Oak Ridge National Laboratory has developed a process for manufacturing composite material components without the need for molds. The technique is inspired by origami: they print the material onto a flexible fabric that is then folded to take the desired shape. This reduces manufacturing time by 95% and costs by 90%, which could make parts for cars or airplanes cheaper.
How mold-free manufacturing works 🛠️
The method uses fiber deposition printing onto a coated textile. Once the flat piece is printed, it is folded following creases calculated by software, similar to the art of origami. The fabric acts as a hinge and reinforcement, eliminating the need for a rigid mold. This allows complex shapes to be created in hours instead of days. The process is viable for large structures, such as fuselage panels or car bodies, and minimizes material waste.
Origami that saves money and headaches 😄
So, while some are still debating whether folding a paper map is art or torture, the folks at Oak Ridge are already folding airplane parts. The best part is, if you lose the instructions, no problem: the software remembers them. That said, you'd better not ask your brother-in-law to assemble the car following a paper-folding tutorial; he might end up with a paper airplane instead of a car.