Conformal morphing meta-cylinders 3D printing for mechanical intelligence programming

This study presents a rotary printing strategy for fabricating multistable tubular meta-cylinders that undergo tension-induced nonplanar morphing and can be nested co-axially to tailor various desired energy absorption responses. The multistable tubular meta-cylinder is derived from a two-dimensional (2D) kirigami structure composed of multiple bistable unit cells. A simulation-driven design workflow is developed to achieve target stability landscapes and predefined cell expansions for controlled shape morphing. The resulting kirigami cell design is then translated into cylindrical G-code, enabling support-free rotary 3D printing of tubular modules. Three diameters of a common kirigami-inspired pattern are manufactured to study size effects and post-tension shape programming from the as-printed cylindrical state to an expanded morphology. Single tubes and co-axial stacks are evaluated under tension, uniaxial compression (crush), and three-point bending, revealing programmable snap transitions, diameter-dependent energy barriers, and geometry-driven stiffness scaling. The co-axis modularity enables mix-and-match assemblies of modular cylinders that deliver targeted energy absorption while minimizing material waste using rotary printing and design combinations. This work establishes rotary-printed, multistable meta-cylinders as a sustainable, reconfigurable platform for protective, robotic, and structural applications.