Design and Fabrication of Origami-Inspired Knitted Fabrics for Soft Robotics

TL;DR

This paper introduces a novel method for designing and fabricating origami-inspired knitted fabrics that combine reconfigurability, structural integrity, and wearability for soft robotics applications.

Contribution

It develops a general design framework translating origami patterns into knitted fabrics with programmable stitches and materials, enabling complex foldable structures in wearable robotics.

Findings

Stitch patterning enhances folding directionality.

Heat fusible yarn stabilizes geometry and prevents out-of-plane deformations.

Successfully reproduces complex origami tessellations and demonstrates a wearable robotic Kaleidocycle.

Abstract

Soft robots employing compliant materials and deformable structures offer great potential for wearable devices that are comfortable and safe for human interaction. However, achieving both structural integrity and compliance for comfort remains a significant challenge. In this study, we present a novel fabrication and design method that combines the advantages of origami structures with the material programmability and wearability of knitted fabrics. We introduce a general design method that translates origami patterns into knit designs by programming both stitch and material patterns. The method creates folds in preferred directions while suppressing unintended buckling and bending by selectively incorporating heat fusible yarn to create rigid panels around compliant creases. We experimentally quantify folding moments and show that stitch patterning enhances folding directionality while the heat fusible yarn (1) keeps geometry consistent by reducing edge curl and (2) prevents out-of-plane deformations by stiffening panels. We demonstrate the framework through the successful reproduction of complex origami tessellations, including Miura-ori, Yoshimura, and Kresling patterns, and present a wearable knitted Kaleidocycle robot capable of locomotion. The combination of structural reconfigurability, material programmability, and potential for manufacturing scalability highlights knitted origami as a promising platform for next-generation wearable robotics.