PopupCAD: a tool for automated design, fabrication, and analysis of laminate devices

Recent advances in laminate manufacturing techniques have driven the development of new classes of millimeter-scale sensorized medical devices, robots capable of terrestrial locomotion and sustained flight, and new techniques for sensing and actuation. Recently, the analysis of laminate micro-devices has focused more manufacturability concerns and not on mechanics. Considering the nature of such devices, we draw from existing research in composites, origami kinematics, and finite element methods in order to identify issues related to sequential assembly and self-folding prior to fabrication as well as the stiffness of composite folded systems during operation. These techniques can be useful for understanding how such devices will bend and flex under normal operating conditions, and when added to new design tools like popupCAD, will give designers another means to develop better devices throughout the design process.