Earwig fan folding with thick panels

Abstract To address the challenges of scaling biologically inspired deployable structures, particularly focusing on translating the compact folding mechanism of earwig hind wings into human-scale engineering applications. Biological folding systems often lose structural efficiency at larger scales due to scaling laws, such as the square-cube law, making thickness and strength critical considerations. We analysed the geometric principles underlying the earwig (Dermaptera) wing-folding mechanism and developed a parametric design methodology to replicate these principles for thick-panel materials. Thickness accommodation techniques derived from origami engineering were integrated into the design to ensure collision-free and structurally feasible folding. Simple prototypes were fabricated to confirm that the proposed folding patterns could be implemented without interference when using panels of finite thickness. The developed design method successfully implemented the complex biological folding mechanism into thick-panel structures suitable for large-scale engineering applications. Deployment experiments demonstrated that the prototypes maintained structural integrity, achieved efficient folding and deployment, and effectively resolved typical issues caused by material thickness. This study offers a practical approach for scaling biological folding mechanisms to human-scale engineering applications, potentially impacting diverse fields such as aerospace, architecture, and deployable structural systems. It contributes to biomimetic engineering by bridging the gap between intricate biological models and practical engineering implementations.