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Geometric Optimization of Origami Tessellations for Lightweight Load‑Bearing Structures

CSEF · 2026 Applied Mechanics (Senior Division)

Joseph Baek

Overview

Lightweight load-bearing structures are widely used in aerospace, protective packaging, and deployable engineering, where reliability depends on resisting compressive collapse. Origami tessellations offer a geometry-based approach for strengthening such lightweight structures, yet unpredictable buckling limits their compressive strength and repeatability, making it challenging to design tessellations that fail consistently under compression. This project investigated whether a novel hybrid design could improve compressive strength and repeatability compared to the waterbomb and the Miura-ori, hypothesizing higher collapse load and reduced variability from a symmetrically densifying waterbomb core and opposing 60-degree Miura-ori load paths. To test this, five samples of each model were folded from 176 gsm, 20 by 20 cm cardstock squares. They were compressed between two acrylic plates as weights were added incrementally to failure, which was defined as the first irreversible collapse. A flat-sheet control (n=3) was tested on corner posts. In testing, the hybrid reached 5970 ± 588 g, 80% higher than Miura-ori and 209% higher than waterbomb, with the lowest variability. While the waterbomb showed localized deformation and asymmetric buckling, the Miura-ori tended to fail via abrupt, global collapse; the hybrid showed delayed, more distributed deformation. Collectively, these results support the hypothesis that combining symmetric densification with two-directional load paths improves compressive stability and repeatability. Overall, these findings indicate that hybrid tessellation design is a promising strategy for lightweight load-bearing cores in deployable and protective applications.

Competition history

  • CSEF 2026 Applied Mechanics (Senior Division) · Entry S-02-14

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