Kirigami inspired shape programmable and reconfigurable multifunctional nanocomposites for 3D structures

[Display omitted] •The kirigami design strategy can achieve a controlled sequential folded honeycomb structure by combining different patterns of hinges.•The sequential self-folding approach allows to accurately position nanoparticles in 3D space and time and, hence, controlling properties and anisotropies.•The multifunctional self-folded honeycomb can go beyond the typical sensing/actuation dichotomy with capabilities to both actuate and sense. The ability to shape and program remotely and contactlessly from two-dimensional (2D) flat multilayer materials into three-dimensional (3D) structures and functional devices could be ideal for applications like space missions, environmental remediation and minimally invasive surgery. However, achieving a fast and accurate deployment of complex 3D shapes contaclessly at low energy consumption, while embedding a number of physical propertiesand functionalities, remains very challenging. Herein, a strategy to widen the complexity space of 3D shapes and functions achievable is demonstrated, by enabling a controlled sequential folding while incorporating nano-reinforcements. Sequential folding was successfully achieved and a honeycomb structurewas developed by designing multilayer polymer films with different kirigami patterns - each responding at a different rate upon heating. A finite element method (FEM) model was developed to better understand the main underlying physical mechanism as well as to feedback into materials and structure design. Moreover, a shape-programmed CNT veil-based honeycomb structure was developed, triggered remotely by thermal stimuli, with capability to self-sense the folding state through the electrical resistance change (ΔR/R0 = 100–300 %). Overall, it was demonstrated that designing layered nanocomposites with different 2D patterns allows an accurate sequential folding into 3D structures, with bespoke physical properties and integrated sensing–actuating functionalities.