Validation of a nonlinear force method for large deformations in shape-morphing structures

Reducing energy and material consumption is a priority for the construction, aerospace, and automotive industries. Shape morphing addresses these concerns by broadening the band of functionality of a structure by adapting its shape to an external stimulus, such as pressure, or an internal stimulus, such as embedded actuation. This work outlines the development of an actuator placement optimization method for overdeterminate lattice structures with the objective of achieving predetermined large shape changes accurately. The deformation is modeled with both a linear and a nonlinear force method to determine their validity for large-shape change and their usefulness for the field of shape morphing. The linear and nonlinear methods are compared in four benchmark problems and two case studies relevant to the field of shape morphing. The nonlinear method is shown to achieve a level of accuracy 10(2) to 10(4) higher compared to FEM simulation, while using 23% fewer actuators and up to 77.3% less elongation of actuators, which makes it more favorable for shape-morphing applications. Two case studies for applications in aerospace and construction show that the nonlinear force method is better equipped for large shape change in overdeterminate meshed freeform target shapes and doubly curved surfaces with a high variable density. However, the nonlinear force method is less computationally efficient than the linear force method, as expected. A judicious choice of constraints can help reduce the run time.