One-degree-of-freedom flat-foldable thick-panel origami-kirigami structures: modular arrays and closed polyhedra

Origami structures hold promising potential in space applications, such as ultra-large-area solar arrays, deployable space stations, and extra-terrestrial modular foldable buildings. However, the development of thick-panel origami structures has been limited, relying on a few typical origami patterns without a comprehensive design theory for multi-crease, multi-vertex thick-panel configurations. Additionally, realizing closed Polyhedra in thick-panel origami presents substantial challenges. Here, we introduce a design methodology inspired by origami and kirigami principles for one-degree-of-freedom (one-DOF) flat-foldable thick-panel origami-kirigami structures, including modular scalable arrays and closed polyhedral structures. The thick-panel origami-kirigami modular scalable arrays incorporate mixed four-crease vertices and (2n + 4)-crease vertices, enabling one-DOF flat-foldability and modular expansion of thick-panel units. The thick-panel origami-kirigami closed polyhedral structures, including tetrahedrons, square pyramids and triangular prisms, possess one-DOF inward-flat-foldability and structural closure after unfolding. This novel design framework for thick-panel origami-kirigami structures is capable of structural design from centimeter to meter scale, validated by kinematic analysis and prototype experiments.