An analytic framework for developing inherently-manufacturable pop-up laminate devices

Daniel M. Aukes, Benjamin Goldberg, Mark R. Cutkosky, Robert J. Wood

Research output: Contribution to journalArticlepeer-review

34 Scopus citations


Spurred by advances in manufacturing technologies developed around layered manufacturing technologies such as PC-MEMS, SCM, and printable robotics, we propose a new analytic framework for capturing the geometry of folded composite laminate devices and the mechanical processes used to manufacture them. These processes can be represented by combining a small set of geometric operations which are general enough to encompass many different manufacturing paradigms. Furthermore, such a formulation permits one to construct a variety of geometric tools which can be used to analyze common manufacturability concepts, such as tool access, part removability, and device support. In order to increase the speed of development, reduce the occurrence of manufacturing problems inherent with current design methods, and reduce the level of expertise required to develop new devices, the framework has been implemented in a new design tool called popupCAD, which is suited for the design and development of complex folded laminate devices. We conclude with a demonstration of utility of the tools by creating a folded leg mechanism.

Original languageEnglish (US)
Article number094013
JournalSmart Materials and Structures
Issue number9
StatePublished - Sep 2014
Externally publishedYes


  • computer aided design
  • design automation
  • manufacturing
  • microfabrication
  • popupCAD
  • popupbook MEMS

ASJC Scopus subject areas

  • Signal Processing
  • Civil and Structural Engineering
  • Atomic and Molecular Physics, and Optics
  • Materials Science(all)
  • Condensed Matter Physics
  • Mechanics of Materials
  • Electrical and Electronic Engineering


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