Metal, Tension-Activated Kirigami for Glass Masonry Interlayers

Abstract

Additive manufacturing and casting enable the fabrication of freeform, three-dimensional glass elements. Yet inherent process constraints typically limit component size to that of a masonry brick. Such glass masonry systems, in turn, require an interlayer material to avoid glass-to-glass contact and reduce stress concentrations. Towards reversible structures, dry-assembled cast silicones, composite materials, and other alternatives have been investigated as replacements for currently used adhesives. This paper investigates metal, tension-activated kirigami as an alternative to dry interlayer systems. It assesses the flexibility, mass, and embodied carbon of kirigami for feasibility in a higher-performance masonry system. This paper uses empirical probabilistic methods to estimate the stiffness and strength of activated kirigami made from paper and steel. Experimental results show that steel kirigami patterns can be designed for applied stresses of 2-20 MPa and stiffness of 9-183 MPa. Empirical models are used to study compatibility with glass masonry in compressive testing of metal kirigami and glass interfaces.  Results show that metal kirigami can be tuned to buckle before damaging glass and have 50-73% lower mass and 8-26% lower embodied carbon than adhesives and previously proposed dry interlayers.