Small-Scale FDM Prototyping for Early Design of Deployable Structures: Telescoping and Origami-Inspired Mechanism Case Studies

Abstract

Collapsible structures may improve the transportation and deployment of temporary housing, but testing occupiable designs requires substantial resources and introduces safety concerns. This study investigated the value of small-scale fused deposition modeling (FDM) 3D printing as an early-stage engineering tool through the design and testing of two collapsible housing designs: a PLA-printed telescoping-shell prototype and a PETG-printed origami-inspired folding prototype. To examine mechanism-specific variables before producing the complete models, 3D printing was used to achieve rapid and inexpensive iteration and thus improve the design geometries. The completed prototypes were then compared through collapsed-versus-expanded dimensions, operation time, and notes on durability. The results showed that 3D printing could accurately help with quick iteration in specific design objectives (in this case, clearance and hinge thicknesses); it could also reveal tradeoffs and comparisons between two geometries and contribute to analysis of their feasibility and robustness. Through this, the study also assessed the viability of two collapsible-housing designs and the positive and negative attributes of each. Small-scale additive manufacturing can therefore reduce early design uncertainty and guide the development of more advanced prototypes.