SCIENCE ADVANCES | RESEARCH ARTICLE

MATERIAL SCIENCE Copyright © 2020

The Authors, some
Computational wrapping: A universal method to wrap rights reserved;
exclusive licensee
3D-curved surfaces with nonstretchable materials American Association
for the Advancement
for conformal devices of Science. No claim to
original U.S. Government
Works. Distributed
Yu-Ki Lee1*, Zhonghua Xi2*, Young-Joo Lee1, Yun-Hyeong Kim1, Yue Hao2, Hongjin Choi1, under a Creative
Myoung-Gyu Lee1, Young-Chang Joo1, Changsoon Kim3, Jyh-Ming Lien2†, In-Suk Choi1† Commons Attribution
NonCommercial
This study starts from the counterintuitive question of how we can render conventional stiff, nonstretchable, and License 4.0 (CC BY-NC).
even brittle materials sufficiently conformable to fully wrap curved surfaces, such as spheres, without failure.
Here, we extend the geometrical design method of computational origami to wrapping. Our computational wrap-
ping approach provides a robust and reliable method for fabricating conformal devices for arbitrary curved surfaces
with a computationally designed nonpolyhedral developable net. This computer-aided design transforms two-­
dimensional (2D)–based materials, such as Si wafers and steel sheets, into various targeted conformal structures
that can fully wrap desired 3D structures without fracture or severe plastic deformation. We further demonstrate
that our computational wrapping approach enables a design platform that can transform conventional non-
stretchable 2D-based devices, such as electroluminescent lighting and flexible batteries, into conformal 3D
curved devices.

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INTRODUCTION is by introducing patterned cuts in the materials. Recent examples
The development of new flexible and stretchable materials has re- of patterned cuts are lattice cut patterns and fractal cut patterns.
cently generated substantial interest in fabricating conformal devices Cho et al. (11) proposed a fractal cut design approach for planar
that can conform to the target three-dimensional (3D) surface (1–5). materials that enabled the production of mechanical metamaterials
However, the application of such materials for practical conformal with a hierarchical auxetic structure. They showed that the fractal
electronics remains strictly limited by the inability to provide cer- cut-designed materials are shape programmable and can effectively
tain key criteria available in conventional electronic products, such cover a sphere. In addition, Konaković et al. (12) suggested computer
as high conductivity and reliability. While the majority of works algorithms for designing complex 3D models using 2D auxetic
involving conformal devices have used soft and stretchable materials, structures. Both studies overcame the limitations of existing flexible
there are a few works that have pioneered conformal devices made materials by geometrically designing cut patterns. However, when
of conventional nonstretchable or brittle materials such as silicon covering complex 3D surfaces, these structures inevitably result in
and metal. Nevertheless, those pioneered works have used the con- openings that lead to the design and functional limitations in con-
ventional materials in a limited area of the devices with very thin formal devices, such as suboptimal coverage of printable batteries and
“patterned structures” such as horseshoe patterns (6–8). In other undesirable holes in lighting and displays (Fig. 1B). To overcome
words, it is still challenging to cover an entire 3D surface with con- this problem, we introduce a computational design strategy called
ventional materials used in the advanced devices (9, 10). This study “computational wrapping with nonpolyhedral developable nets” to
introduces a universal method to use conventional nonstretchable make a 2D nonstretchable material platform to fabricate wearable
materials to reliably wrap arbitrary 3D curved surfaces, including and conformal devices.
the human body and curved vehicle interiors, as potential applica-
tions. This approach allows us to make conformal devices without
sacrificing performance. RESULTS AND DISCUSSION
Figure 1A shows that wrapping a sphere with a rectangular piece Figure 1C shows a series of snapshots that illustrate the 2D unfolding
of paper inevitably results in the formation of wrinkles, crumples, of a sphere generated automatically by our polyhedral edge unfolding
and overlaps regardless of the material type, including stretchable algorithm, which is used to wrap a steel ball. Theoretically, a curved
sheets. If the material is a substrate or another active layer of a flexible surface can be characterized by the Gaussian curvature, which is the
device, then severe material deformation and overlapping can cause vector product of the maximum and minimum principal curvatures
the material to fracture or break, as shown in fig. S1 and movie S1. at a point. A 2D material with zero Gaussian curvature at all points,
One common way to wrap 3D surfaces with nonstretchable materials such as a sheet of paper, is called a developable surface. A develop-
able surface cannot be transformed into a nondevelopable 3D sur-
1
face with positive or negative Gaussian curvatures without tearing,
Department of Materials Science and Engineering, Seoul National University,
Seoul 08826, Republic of Korea. 2Department of Computer Science, George Mason
stretching, or compressing the material. This has been mathemati-
University, Fairfax, VA 22030, USA. 3Graduate School of Convergence Science and cally proven by the “Gauss Theorema Egregium,” which states that
Technology, and Inter-University Semiconductor Research Center, Seoul National “To move a surface onto another surface, the Gaussian curvature of
University, Seoul 08826, Republic of Korea. all corresponding points must match” (13) (fig. S2). Instead, poly-
*These authors contributed equally to this work.
†Corresponding author. Email: [email protected] (J.-M.L.); [email protected] hedral edge unfolding (14, 15) flattens arbitrary surfaces into 2D
(I.-S.C.) structures by cutting the surface into developable patches with C0

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Fig. 1. Reverse engineering computational origami for conformal wrapping. (A) Wrinkles are formed when tightly wrapping a rectangular sheet of paper around a
nonzero Gaussian surface. (B) Fractal cut patterns can avoid wrinkles but inevitably lead to openings and uncovered areas. (C) The 2D unfolding of a spherical polyhedron
generated automatically by computational origami can wrap a steel ball without leaving uncovered areas. (D) As the number of facets increases, the smoothness and
conformability of the mesh naturally improve. The difference in surface area between the perfect sphere and the approximated polyhedra decreases by 5.3% when the
number of facets increases from 80 to 500. The Hausdorff distance between the polyhedral surfaces and the perfect sphere also reduces from 7.05 to 1.17% of the radius
of the perfect sphere when the number of facets increases from 80 to 500 (see also fig. S4). (Photo credit: Y.-K. Lee, Seoul National University.)

continuity; i.e., the patches are connected without gaps and seams. methods (fig. S3). Figure S3A shows the “steepest edge (SE) unfolding”
The computer science community has recently exerted great efforts (16). Given a polyhedron P and a 3D vector c​​ →​​, SE unfolding associ-
< c, v − w >
to algorithmically determine surface cuts that segment a nondevel- ates each edge e = (v, w) of P with a weight ​​_ ∣ v−w ∣
 ​,​ where v and
opable surface into developable surface patches called polyhedral w are the end points of e and <, > denotes the inner product between
nets (or simply nets) (16–18). Beyond designing valid nets, recent two vectors. Then, for each vertex v, the edge incident to v with the
computational methods, including those developed by the authors largest weight, i.e., the edge most aligned with ​​ c→​​, is cut. The SE un-
(19–22), have focused on optimizing net quality and foldability using folding can unfold nearly all convex polyhedra with a few randomly
machine learning techniques that drastically reduce the time and selected ​​ c→​​, creating radially spread unfolded figures. Other methods,
effort needed relative to traditional trial-and-error approaches. such as flat-tree unfolding (fig. S3B) (16) and genetic algorithm (GA)
A polyhedron can have multiple possible polyhedral nets (23), methods (22, 24), are also available to unfold nonconvex polyhedra
especially when the polyhedron is convex. For a given polyhedral (fig. S3C). As it is critically important that a conformal device is
sphere, we demonstrate six unfoldings created by six different composed of one or as few pieces as possible, our recently developed

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GA method can evolve the unfoldings by mutating the edge weights can be enclosed by a developable surface; however, there will always
until a net with zero overlaps is found (22). This evolution is con- be spaces between these two surfaces. To control the size of this
trolled by a fitness function f : N → ℝ that evaluates an unfolding. space, we adaptively refine the facet mesh until the two-sided Hausdorff
An example of f(N) is defined as follows distance between the developable surface formed by the polyhedral
net and the wrapped object is bounded. More specifically, we mod-
f(N) = − (​​  0​​​​  0​​ + ​​  1​​​​  1​​)​
​ ify the GA fitness function in our edge unfolding method as follows

where 0 is the number of overlaps in N, 1 is the number of hyper-

f(N) = min(− (​​  0​​​​  0​​  + ​​  1​​​​  1​​) , ​∑ ​e​ i​​​ ​​​​  ​e​ i​​​​)​
​
bolic vertices that cause local overlaps in N, and 0 and 1 are user
parameters, which are set to 100 and 1, respectively. The maximum
value of f(N) must be 0. In addition, three more unfolding algo- where ei is the dihedral angle of a cut edge ei in the polyhedral
rithms are presented in fig. S3. Although all of these algorithms can net N. This enhanced f(N) further evolves N to minimize the sum of
be used depending on the required application, we chose the SE un- the folding angles, and the net is thus optimized for bending by
folding and GA methods to further illustrate our notion of wrap- maximizing f(N). After obtaining a polyhedral paper net with min-
ping a 3D curved surface via computational unfolding methods. imal folding angles (Fig. 2A, top), we use the outer cut lines of the
Figure 1D illustrates four different unfolding paper structures net but ignore (erase) all the crease lines; the result is called a non-
that were fabricated from four polyhedral spheres with different polyhedral developable net (Fig. 2A, bottom). The distance between
resolutions via the computational SE unfolding method. To ensure the target shape and the developable surface formed by its non-
that the polyhedral sphere can tightly enclose a perfect sphere so polyhedral developable net (referred to as “developable net” herein-
that the facets of the polyhedron touch the perfect sphere, the poly- after) is calculated. Our method then determines the areas that

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hedral sphere must be properly scaled. Consequently, to ensure the require more detailed tessellation, e.g., areas with high Gaussian
enclosure of the perfect sphere, the radius and surface area (4r2) curvature, and repeats the process (remeshing, unfolding, and dis-
of the polyhedron with 80 facets are 7.05 and 6.38% larger than tance estimation) until the distance is sufficiently short. Therefore,
those of a perfect sphere, respectively. The difference in the radii of given a polyhedral net with a high-resolution mesh, because there is
the polyhedral sphere and the perfect sphere decreases to 1.17% a small distance between the perfect sphere and the developable
when the number of facets increases to 500. The area difference is surface formed by its developable net, we can ignore (erase) all the
also reduced as the mesh number increases, resulting in a 1.09% crease lines and simply bend and press the strips of the developable
difference for a polyhedron with 500 facets (fig. S4). Consequently, paper net to tightly wrap the sphere, creating controlled and bounded
increasing the resolution of meshes for paper polyhedra provides spaces between the net and the sphere without gaps or overlaps be-
better conformability on the steel ball, as shown in fig. S4D. In tween facets (see fig. S4 regarding the required mesh numbers for
many applications of conformal devices, accurate covering and smooth wrapping). Consequently, this fabrication process can ac-
tight wrapping are crucial. In addition, because most real-world ob- curately produce highly complex and smooth 3D surfaces and is
jects are smooth and curved, high-resolution meshes are needed to many times faster than the conventional computational folding
provide the necessary covering accuracy. However, there are still method when handling complex shapes because there is no creasing
issues in folding the creases to cover the surface, which requires a and folding involved in the wrapping procedure. Moreover, we note
long folding time during fabrication and possibly causes mechan- that the small bending angles of the strips possibly prevent the ma-
ical fracture or plastic deformation of the materials used, leading to terials used in conformal devices from being damaged when wrap-
electrical failure in devices. Here, we develop an approach called ping an object.
“computational wrapping,” which goes beyond the conventional This computational wrapping scheme based on developable nets
computational folding method. By considering conformal device enables our method to be applied not only to papers but also to
design as a paper wrapping problem instead of a paper folding metallic and ceramic materials. For the same developable net gener-
(origami) problem, we recognize that the operations of attaching ated with 500 meshes, a stainless steel sheet can tightly wrap a steel
and wrapping conformal devices to cover an underlying curved ball, as shown in Fig. 2 (B and C). Moreover, we can even apply our
3D surface are made much easier by bending and pressing a poly- method to brittle Si wafers. We fabricated a computational wrap-
hedral net without creases than by creasing and folding, as illus- ping pattern for a Si wafer to cover part of a sphere with a diameter
trated in Fig. 2A. of 4 cm, as shown in Fig. 2D. A thin Si wafer with a thickness of
Paradoxically, we found that in this bending and attaching ap- 20 m was cut by laser cutting based on a computed developable net
proach, high-resolution meshes provide us with the needed solution consisting of 400 meshes without crease lines (Fig. 2, D and E). We
to address the limitations of long fabrication times and mechanical attached this wafer to both convex and concave surfaces without
reliability. A mesh with high-resolution tessellation can better rep- noticeable gaps, overlaps, or fractures (Fig. 2F). A finite element
resent surfaces with a higher degree of continuity (e.g., G1 continuity (FE) analysis of the Si wafer in Fig. 3 provides more quantitative
along the branches where facets on both sides of a crease line share mechanical analysis supporting the assertion that the computa-
a common tangent direction), which is common for many surfaces tional wrapping process for the Si wafer is mechanically reliable.
formed by real materials. The wrapping process is realized in the FE simulation by compress-
Computationally, this goal is achieved by ensuring that the dis- ing the developable net between the sphere and a concave mold of a
tance between the wrapped object and the developable surface is wrapped part of the sphere (Fig. 3A and movie S2). In the FE simu-
smaller than a user-provided value based on the required wrapping lation, the radius of the sphere is set to 2 cm, replicating the radius
tightness and the material properties. For example, a surface with of the sphere used in the experiment (Fig. 2G), and the radius of the
nonzero Gaussian curvature everywhere, such as a perfect sphere, concave mold is set to the sum of 2 cm and the 2D net thickness. The

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Fig. 2. Concept and physical demonstration of computational wrapping. (A) When the sum of the folding angles of a net is minimized, the crease lines can be ignored
to accommodate flexible but nonstretchable stiff and brittle materials. For 500 meshes, the gaps in the case of a rigid material and the wrinkles in the case of a flexible
material are no longer visible, and the difference between the two becomes imperceptible. (B) A nonstretchable stainless steel sheet is cut into a developable net. (C) With
a sufficient number of meshes, the stainless steel sheet can be bent and fully wrap a sphere without creasing or folding. (D) Part of the sphere is unfolded with 400 meshes,
and the crease lines are removed. (E) A 20-m-thick brittle Si wafer is cut into an unfolded net with a laser cutter. (F) The cut Si wafer stably wraps both convex and concave
frames. (Photo credit: Y.-K. Lee, Seoul National University.)

developable nets with different numbers of meshes are generated increases from 50, 100, 200, to 400. Consequently, the highest value
by the GA method, and the computational models for the FE sim- of the maximum in-plane principal stress in Fig. 3E decreases from
ulation are constructed with adaptive meshing (Fig. 3B). 624 MPa for 50 meshes to 193 MPa for 400 meshes. These stress
Figure 3C shows that for the 20-m-thick Si wafer wrapping values are much smaller than the fracture strength of the Si wafer,
the part of the sphere, the maximum in-plane principal stress dis- which is approximately 5 GPa (25, 26). This finding clearly indi-
tribution indicates that the stress decreases as the number of meshes cates that by maximizing f(N), the bending angles of the strips are

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Fig. 3. FE analysis. The mechanical reliability of the computational wrapping of the Si wafer shown in Fig. 2F is further investigated through FE simulations for wrapping
a part of a sphere. (A) The wrapping process is simulated by compressing the 2D nonpolyhedral developable net between the sphere and a concave mold of a wrapped
part of the sphere (see also movie S2). The radius of the sphere in the FE simulation is identical to that used in our experiment (Fig. 2F). (B) The nonpolyhedral developable
nets are generated by the GA method. The distributions of the maximum in-plane principal stress for the wrapped Si wafers are analyzed (C) with respect to the number
of meshes at a fixed thickness of 20 m and (D) with respect to the thickness at 400 meshes. Consequently, the maximum in-plane principal stress decreases as the number
of meshes increases and increases as the thickness increases (E and F). In both cases, the maximum stress values are much smaller than the fracture strength of the Si wafer.

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Fig. 4. Demonstration of conformal devices. (A) Cuttable, nonstretchable, commercial EL panels consisting of brittle electrodes are cut with a laser cutter to form de-
velopable nets for a sphere. (B) EL panels with a developable net can fully cover a sphere and (C) operate without catastrophic failure. (D and E) The computational
wrapping concept is also demonstrated for an ellipsoid model (see fig. S6). (F and G) In addition to a sphere and an ellipsoid, a commercial Korean facial mask can also be
conformably covered with EL panels and operated without electrical failure (fig. S7). (H) An electric toy vehicle can also be conformably wrapped with EL panels in the
same manner, and the attached EL panels also operate well without failure. The GA unfolding method is used for generating the developable net for parts with nonzero
Gaussian surfaces, including (I) the headlights, the edge of the front side bumper, and (J) the edge of the rear side bumper of the electric toy vehicle (fig. S8). (Photo
credit: Y.-K. Lee, Seoul National University.)

minimized to ensure minimal stress and strain, thereby preventing thicknesses (20, 50, 100, and 125 m), and the results are shown
the occurrence of fracture or severe plastic deformation. We in Fig. 3D. The residual stress is developed throughout the devel-
also simulated the maximum in-plane principal stress distri- opable net as the thickness increases to 125 m. The highest value
bution in the wrapped Si wafer with 400 meshes under various of the maximum in-plane principal stress is 1.093 GPa, which is

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still less than the fracture strength of the Si wafer (see fig. S5 for an shape without forming crease lines between adjacent facets. Con-
additional FE analysis of a stainless steel sheet). sequently, stiff or even brittle materials, such as metal sheets or Si
The above results have significant practical implications. Most wafers, can fully cover and tightly wrap nonzero Gaussian curvature
flexible devices are made from 2D brittle substrate materials that surfaces without catastrophic fractures. We demonstrated that the
can be slightly bent at a small angle only if the aspect ratio is suffi- advantages of wrapping over folding can be applied to make real
ciently large (27). As long as we can make 2D unfolding structures, conformal devices from conventional devices, such as EL lighting
we can use conventional materials and processes, such as deposition devices and batteries. Our universal computational wrapping method
and evaporation to wrap a curved surface with a conformal device. provides new insights into the development of conformal devices
Hence, these structures lead to a significant increase in the applica- with arbitrary shapes using efficient algorithms with robust and re-
bility of computational origami to real industrial fabrication pro- liable conventional fabrication processes.
cesses, wherein wrapping can be used instead of folding to fabricate
conformal devices. For instance, in this study, we realize a confor-
mal device using commercial electroluminescent lamp (EL) panels. MATERIALS AND METHODS
We simply use a laser cutter to cut the commercial EL panels, in- Computational methods
cluding the power supply terminals at the end of an edge site, corre- The nonpolyhedral developable net was generated by our computa-
sponding to the computationally generated developable net of a tional algorithm. We implemented the computational unfolding
sphere and an ellipsoid with 500 meshes. The final cut EL panels can algorithm in C++, and the executable file can be found at http://
be stably and easily attached to the sphere (Fig. 4, A to C) and the masc.cs.gmu.edu/wiki/OrigamiSoftware. The 3D surface models
ellipsoid (Fig. 4, D and E, and fig. S6). The EL panels consist of top for the traditional Korean mask and the electric toy vehicle were
and bottom brittle electrodes with solid interlayers (including an obtained by 3D scanning followed by meshing with MeshLab soft-

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indium tin oxide conductive layer) that can be easily fractured by ware. The mechanical reliability of computational wrapping was
creasing and folding. However, no catastrophic failures occurred verified through FE simulations [ABAQUS/Explicit (version 6.14)],
during the fabrication process, and the 3D conformal device exhib- wherein a part of a sphere was wrapped. The computational models
ited good operation, as shown in Fig. 4 (C and E), because we con- for the FE simulations were constructed with adaptive meshing.
formally wrapped the sphere by bending and pressing rather than The orthotropic values in Voigt notation shown below were used as

⎢⎥⎢ ⎥⎢ ⎥
creasing and folding. In addition to a sphere and an ellipsoid model, the mechanical property inputs for the Si wafer
a traditional Korean mask was conformably wrapped by EL panels.
We used 3D scanning to obtain a 3D model and generate meshes ⎡​​  11​​⎤ ⎡165.6 63.9 63.9 0 0 0 ⎤⎡​​  11⎤​​
for the most curved region of the mask. For the traditional Korean
​​  22​​ 63.9 165.6 63.9 0 0 0 ​​  22​​
​​  33​​ ​​  33​​
mask model, a total of 169 meshes are used for the target region, ​​​ ​ ​​​ ​   ​​​​​ ​​  = ​ ​​​ 63.9 ​​ ​​63.9 ​​ ​165.6
​ ​​​  0​​  ​​  0​​  ​​  0​​  ​​ ​​​ ​​​​​  23​​ ​​​ ​​  [GPa]​​
23
​​​   ​​​​ 0
​  ​ 0
​  ​ ​  ​ 0
​  ​​  ​ 79.6
​  ​ ​  ​ 0 0
​ ​ ​ ​​  ​ ​ ​​  ​ ​​​   ​​​​
which are unfolded with the SE unfolding method without overlap-
⎣​​  12⎦​​ ⎣ 0
0​ ​ ​ 0​ ​​  0​ ​​  0​ ​​  79.6 ​ ​ 0​ ​ ​ ​
0 0 0 79.6⎦⎣​​  12​​⎦
31 31
ping (Fig. 4, F and G, and fig. S7). Last, the EL panel with a develop- ​ ​ ​  ​
0
able net was conformally attached to the mask, and the panel exhibited
good operation without failure. The concept was applied for com- The wrapping process was simulated by compressing the 2D
plex exterior parts of an electric toy vehicle with a nonzero Gaussian nonpolyhedral developable net between the sphere and a concave
surface. We generated the meshes and the corresponding develop- mold of a wrapped part of the sphere (movie S2). The radius of the
able net via the GA unfolding method, as shown in fig. S8, and then sphere was set to 2 cm, replicating the radius of the sphere used in
EL panels were cut and attached to the surfaces to decorate the our experiment (Fig. 3G), and the radius of the concave mold was
exterior car parts (Fig. 4, H to J, fig. S8, and movie S3). We also fab- set to the sum of 2 cm and the 2D net thickness.
ricated a conformal primary battery. For battery fabrication, the
diversity of the developable net can yield advantages in terms of Experimental methods
manufacturing efficiency and printing material waste reduction for Cardstock papers, 100-m-thick stainless steel sheets, and a 20-m-
screen prints (fig. S9). thick Si wafer were used to demonstrate wrapping a steel ball with
In summary, we introduced the concept of computational wrap- nonstretchable materials. The commercial EL lighting panels were
ping to transform nonstretchable 2D flexible devices into 3D con- used to realize a computationally wrapped conformal device. The
formal devices. A surface with nonzero Gaussian curvature, such as cardstock papers and EL lighting panels were cut into developable
a perfect sphere, can be enclosed by a developable surface, but there nets with a cutting plotter (Cricut cutting machine), whereas the
will always be spaces between these two surfaces. The proposed stainless steel sheets and Si wafer were cut with a laser cutter. All the
computational method controls the distance between these two sur- developable nets were attached to the 3D curved surfaces with
faces to ensure sufficiently tight wrapping. Although approximating double-sided tape.
an arbitrary surface with developable surfaces has also been studied
in the past, all existing works break the surface into multiple sepa-
SUPPLEMENTARY MATERIALS
rated developable surfaces. Our work produces a single connected Supplementary material for this article is available at http://advances.sciencemag.org/cgi/
surface, called nonpolyhedral developable net, which is a conformal content/full/6/15/eaax6212/DC1
wrapping design of a 2D sheet for any 3D surface. Nonpolyhedral
developable net enables applications that require connectivity and con-
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