Laser cutting is a powerful fabrication tool for rapidly creating 3D objects from 2D sheet materials. While most research has focused on making these constructions robust and rigid, we expand this area by introducing robust yet compliant laser-cut structures. We present FlexiFab, a method for fabricating load-bearing volumetric objects with tunable stiffness. The core of our approach is to utilize planar lattice structures for programmable compliance, integrated into a robust framework via an orthogonal interlocking assembly. By interlocking these elements, the planar sheets provide mutual lateral support that prevents out-of-plane buckling and structuralfailure. We also incorporate standard threaded nuts into the assembly, which not only provide structural reinforcement but also allow users to customize local or global stiffness post-fabrication. We demonstrate these benefits through applications such as an adjustable bike seat and provide a parametric design tool to facilitate the end-to-end design process.
Publication
Deying Pan, Fanqi Zhou, Yitao Fan, Guanyun Wang, Alexandra Ion. 2026. FlexiFab: Laser-Cutting Volumetric Compliant Structures with Tunable-Stiffness. In Proceedings of UIST ’26. Detroit, MI, USA. November 2-5, 2026. DOI: https://doi.org/10.1145/3830398.3830570