Bending-active structures are formed from elastic elements that deform into a desired shape. While inverse design algorithms have been developed to optimize each element’s geometry for a specific form, this approach often prevents the reuse of components and limits opportunities for efficient, scalable fabrication.

This project introduces a computational framework to rationalize bending-active structures into a minimal, reusable kit-of-parts (KOP). Instead of designing custom elements for each structure, our method identifies optimal geometries that can be shared across multiple designs. To manage the complexity of assigning parts to different assemblies—a process that becomes computationally intractable through exhaustive search—we propose a continuous optimization strategy. This approach integrates a physics-based simulation that accurately models elastic deformation, enabling effective exploration of the trade-off between fabrication simplicity and design fidelity.

We apply our framework to three distinct classes of bending-active structures, demonstrating how a shared kit of parts can reduce fabrication effort while supporting design versatility and sustainability.