Multiscale structural behaviour of self-transforming chain mail beams: Geometric trends and scale-dependent interactions

3D chain mail assemblies have recently emerged as a promising class of self-transforming structural systems, yet their behaviour at larger scales remains poorly understood. In particular, it is unclear whether geometric outcomes observed in small prototypes persist when the same interlocking assembly is enlarged. This study investigates the multiscale behaviour of a gravity-actuated 3D chain mail curved-beam configuration realised at three geometric scales (1:10, 1:2 and 1:1). Using physical prototyping and 3D scanning, global form is evaluated through span–height outcomes and curvature-profile fitting, while local interaction is characterised through intermodular opening angles as an indicator of how jamming develops along the beam during self-transformation. Results show that, despite increased weight and changes in surface friction with scale, the global curvature profile remains consistently well described by the Catenary model across all scales tested. In contrast, dimensional proportions and intermodular opening angle distributions vary with scale, with greater non-uniformity at full scale. Together, these findings show that robust global curvature can coexist with scale-sensitive local interaction behaviour, highlighting comparative geometric trends and scale-dependent interaction patterns across scales and providing insight into the multiscale behaviour of 3D chain mail beam assemblies.