A biologically inspired concept is investigated which can be utilized to develop energy efficient, lightweight and applicational flexible adaptive structures. Building a real life morphing unit is an ambitious task as the numerous works in the particular field show. Summarizing fundamental demands and barriers regarding shape changing structures, the basic challenges of designing morphing structures are listed. The concept of Pressure Actuated Cellular Structures (PACS) is arranged within the recent morphing activities and it is shown that it complies with the underlying demands. Systematically divided into energy-related and structural subcomponents the working principle is illuminated and relationships between basic design parameters are expressed. The analytical background describing the physical mechanisms of PACS is presented in concentrated manner. This work focuses on the procedure of dimensioning, realizing and experimental testing of a single cell and a single row cantilever made of PACS. The experimental outcomes as well as the results from the FEM computations are used for evaluating the analytical methods. The functionality of the basic principle is thus validated and open issues are determined pointing the way ahead.

Shape-variable structures can change their geometry in a targeted way and thus adapt their outer shape to different operating conditions. The potential applications in aviation are manifold and far-reaching. The substitution of conventional flaps in high-lift systems or even the deformation of entire wing profiles is conceivable. All morphing approaches have to deal with the same challenge: A conflict between minimizing actuating forces on the one hand, and maximizing structural deflections and resistance to external forces on the other. A promising concept of shape variability to face this challenging conflict is found in biology. Pressure-actuated cellular structures (PACS) are based on the movement of nastic plants. Firstly, a brief review of the holistic design approach of PACS is presented. The aim of the following study is to investigate manufacturing possibilities for woven flexure hinges in closed cellular structures. Weaving trials are first performed on the material level and finally on a five-cell PACS cantilever. The overall feasibility of woven fiber reinforced plastics (FRP)-PACS is proven. However, the results show that the materials selection in the weaving process substantially influences the mechanical behavior of flexure hinges. Thus, the optimization of manufacturing parameters is a key factor for the realization of woven FRP-PACS.

Abstract. Flexible cellular 3D structures with structure-inherent compliance made of fiberreinforced composites have repeatedly aroused the interest of international research groups. Such structures offer the possibility to meet the increasing demand for flexible and adaptive structures. The aim of this paper is the development of cellular 3D structures based on weaving technology. Considering the desired geometry of the 3D structure, algorithms are developed for the formation of geometry through tissue sub-areas. Subsequently, these sub-areas are unwound into the weaving level and appropriate weave patterns are developed. A particular challenge is the realization of compliant mechanisms in the woven fabric. This can be achieved either by combining different materials or, in particular, by implementing large stiffness gradients by means of varying the woven fabrics thickness, whereas differences in wall thickness have to be realized with a factor of 1:10. A manufacturing technology based on the weaving process is developed for the realization of the developed 3D cellular structures. To this end, solutions for the processing of hybrid thermoplastic materials (e.g. tapes), solutions for the integration of inlays in the weaving process (thickening of partial areas), and solutions for tissue retraction, as well as for the fabric pull-off (linear pull-off system) are being developed. In this way, woven cellular 3D structures with woven outer layers and woven joint areas (compliance) can be realized in a single process step and are subsequently characterized.

No abstract