Researchers at Oak Ridge National Laboratory (ORNL) have developed a hybrid 3D printing process that combines origami-inspired design with composite materials.

The technique, demonstrated at the Department of Energy’s Manufacturing Demonstration Facility, eliminates the need for costly molds while enabling lightweight, foldable structures.

The researchers deposited materials directly onto a flexible fabric base. This created flat panels that can be folded into complex three-dimensional forms, merging flexible and rigid elements in a single integrated component.

Their approach addresses key limitations in traditional composite manufacturing, which often requires expensive molds and long lead times.

New method ‘redefines’ 3D printing

The ORNL team’s process uses a high-strength fabric substrate, such as nylon, glass fiber, or resin-infused fibers. An integration layer, typically thermoplastic polyurethane, meanwhile, ensures adhesion.

Reinforcing materials are then deposited, including thermoplastic carbon-fiber acrylonitrile butadiene styrene (ABS) for lightweight strength or thermoset resins like epoxy for greater stiffness and durability. The materials form molecular-level bonds, resulting in a robust, unified structure.

“This pioneering method redefines advanced manufacturing by fusing material science with transformative design principles,” Steven Guzorek, lead researcher at ORNL, explained in a statement. “By applying origami-inspired principles to hybrid composites, we are improving the efficiency and scalability of large-structure manufacturing and achieving forms unattainable with traditional additive approaches.”

Guzorek added that material compatibility is key to the new method. “By understanding the materials science, we chose materials that we knew would bond effectively, producing a truly integrated component,” he said.

Cutting fabrication time and cost

The new method is capable of producing complex geometries and structures larger than the printing equipment itself.

In tests, the mold-free method cut fabrication time by 95 percent and reduced costs by 90 percent for a specific design when compared with conventional approaches. It also eliminated challenges associated with mold storage and enabled rapid production of both thermoplastic and thermoset composites.

The technology has the potential to expand design flexibility for industries requiring strong, lightweight parts, such as aerospace, automotive, and construction. Flat printing followed by folding supports efficient transport and on-site assembly, potentially transforming how large-scale components are manufactured.

ORNL has filed a patent for the innovation and is preparing it for licensing to manufacturers. Next, the research team aims to scale the process for broader industrial adoption. They hope it will unlock whole new design possibilities.

“Our goal is to make this innovation scalable so manufacturers across industries can harness its potential,” Guzorek said. “By broadening access to mold-free hybrid composites, we’re empowering manufacturers to explore new design possibilities and unlock entirely new applications for this transformative technology.”

As industries seek lighter and more adaptable materials, ORNL’s origami-inspired method could accelerate innovation in high-performance applications.

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