en.Wedoany.com Reported - Researchers at the Manufacturing Demonstration Facility of the U.S. Department of Energy's Oak Ridge National Laboratory (ORNL) have developed a hybrid 3D printing method that combines origami-inspired design with composite materials to produce flat, foldable structures without the need for molds. Tests show that this process reduces manufacturing time by 95% and costs by 90% compared to traditional mold-based methods.

Lead researcher Steven Guzorek stated that the method integrates materials science with transformative design principles. This mold-free additive process deposits hybrid materials (materials made from mixed reinforcement components) onto a flexible fabric surface. By precisely controlling the shape and strength of the material, it creates flat, foldable structures that combine flexible and rigid components.

The structural substrate uses high-strength fabrics such as nylon, fiberglass, or resin-impregnated composite fibers. An integrated or adhesive layer, such as polyurethane, is then applied to ensure compatibility. Finally, a reinforcement layer, such as carbon fiber-reinforced acrylonitrile butadiene styrene (ABS) or thermosetting resins (e.g., styrene-based or epoxy-based formulations), is deposited. The materials bond at the molecular level, forming a strong connection.

The research team also includes Ahmed Arabi Hassen, Katie Copenhaver, Duncan Frazier, Brian Post, and Tyler Smith. ORNL has filed a patent application, and the team is preparing to make the technology available for future licensing.

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