Kirigami-based inverse design for 3D surfaces formed by mechanically guided method

The mechanically guided assembly method utilizes the compressive buckling behavior of thin-film structures to transform two-dimensional (2D) precursors into three-dimensional (3D) structures. Previous research has shown that by inverse designing thickness and width distributions in 2D precursors, various 3D surfaces with target geometries can be accurately assembled. However, the variation in thickness poses significant challenges for the fabrication of the 2D precursor, especially on a small scale. In this paper, we propose a Kirigami-based inverse design framework that utilizes pre-specified incision patterns as critical parameters to control the bending stiffness distribution of 2D precursors. This enables the fabrication of target 3D structures with constant thickness, which greatly simplifies the production of 2D precursors. By studying the deformation characteristics of beam models during pure bending, we have established an analytical relationship between incision patterns and bending stiffness distribution. To validate the effectiveness of our inverse design theory, we conducted a series of simulations and experiments on 3D structures, yielding favorable comparison results. Moreover, guided by this inverse design theory, we have developed a microneedle structure through conceptual design, demonstrating the capability of Kirigami patterns in the inverse design of complex 3D structures, and highlighting the potential application of our method in the biomedical field.