Modular Synergy and Parametric Regulation of Dual‐Material Deformable Unit Cell Configuration

Deformable structures show great potential in robotics, aerospace, and automotive engineering, owing to their dynamic adaptability, multifunctionality, and programmability.However, existing research is limited to single deformation modes or static mechanical properties, failing to meet the diverse demands of dynamic operational scenarios. To overcome these limitations, this study proposes a modular deformable unit design method based on fused deposition modeling technology using polylactic acid/thermoplastic polyurethane dual materials. By precisely controlling geometric parameters (wall inclination angle α , material spacing X , material inclination angle β ) and process parameters (printing temperature 220 °C, layer thickness 0.2 mm), modular deformable structures with multimodal cooperative deformation capabilities are constructed. A systematic unit partitioning strategy and screening criteria are established, enabling the development of a unit library incorporating various deformation modes, including expansion, bending, and torsion. Numerical simulations and experimental validation demonstrate that this design can synergistically achieve multiple deformation modes, including expansion (−26.82 to 37.91 mm), bending (−39.62° to 46.44°), and twisting (−43.23° to 43.23°). Results show adaptive controllable deformation of multiple degrees of freedom multimodular structures via synergistic modular design integrating unit cell programmable deformation.