We propose a method to fabricate objects composed of 3D printed flattened pieces with integrated zipper-like structures. The object is manually assembled into a 3D shape by connecting the zipper components. By employing a zipper design that allows for angle-independent connections between patches, our method enables both the surface and zipper components to be printed in the same orientation, resulting in high-quality reconstruction of the input model with a faster 3D printing process that wastes less material. We implement a fully automated pipeline that takes a 3D model as input, converts it into developable patches, generates the zipper structures, and flattens them for subsequent 3D printing. We demonstrate that our approach significantly reduces the fabrication time and support material consumption. We also present application examples that highlight the versatility of our method.

We present a computational approach for designing freeform structures that can be rapidly assembled from initially flat configurations by a single string pull. The target structures are decomposed into rigid spatially varied quad tiles that are optimized to approximate the user-provided surface, forming a flat mechanical linkage. Our algorithm then uses a two-step method to find a physically realizable string path that controls only a subset of tiles to smoothly actuate the structure from flat to assembled configuration. We initially compute the minimal subset of tiles that are required to be controlled with the string considering the geometry of the structure and interaction among the tiles. We then find a valid string path through these tiles that minimizes friction, which will assemble the flat linkage into the target 3D structure upon tightening a single string. The resulting designs can be easily manufactured with computational fabrication techniques such as 3D printing, CNC milling, molding, etc. in flat configuration that, in addition to manufacturing, facilitates storage and transportation. We validate our approach by developing a series of physical prototypes and showcasing various application case studies, ranging from medical devices, space shelters, to architectural designs.