Researchers at the Massachusetts Institute of Technology (MIT) have developed a design method that allows complex three-dimensional structures to emerge from a flat configuration with a single pull of a string. This approach offers clear benefits for designers working on portable, space-saving and rapidly deployable solutions. Moreover, it supports sustainable and circular design strategies by reducing material use during transport and storage.

From Flat Panels to Functional Forms

The process starts with a digital 3D design. The system then converts this design into a flat layout of interconnected tiles. Rotating hinges connect the tiles, while a carefully optimised string path guides the transformation. When the user pulls the string once, the structure folds into its final curved form. When released, it returns to its flat state.

As a result, designers can store and transport complex objects efficiently. For architects and interior designers, this opens up new possibilities for temporary pavilions, emergency shelters and flat-pack furniture. Meanwhile, product and packaging designers can explore compact products that deploy only when needed.

Inspired by Kirigami and Auxetic Structures

The method draws inspiration from kirigami, the Japanese art of cutting materials to create movement and flexibility. Here, the flat layouts consist of auxetic tiles. These tiles become thicker when stretched and thinner when compressed. Because of this behaviour, the material transitions smoothly from flat to volumetric while maintaining structural stability.

In addition, an algorithm calculates the minimum number of lift points and determines the shortest possible string route. By minimising friction, the system ensures smooth and reliable deployment. Importantly, the method remains independent of fabrication technique. Designers can use 3D printing, CNC milling or moulding. Multi-material production is also possible, for example by combining flexible hinges with rigid surfaces.

Scalable, Adaptable and Sustainable

The researchers tested the method at different scales. They developed small medical devices such as splints and posture correctors, as well as a human-scale chair assembled by one person. Because the system is scale-independent, it could also support architectural components or modular building structures assembled on site.

From a sustainability perspective, flat transport reduces volume, weight and emissions. Therefore, when combined with biobased or recycled materials, the approach fits well within circular design principles.

Designing for Rapid Deployment

Looking ahead, the MIT team plans to explore self-deploying mechanisms and larger architectural applications. As designers increasingly seek flexible and resource-efficient solutions, this research highlights how intelligent material systems can support fast deployment with minimal waste.

Source: MIT