Fabrication of polymer and carbon polyhedra through controlled cross-linking and capillary deformations

Fabrication of polymer polyhedral structures is achieved by first producing origami sheets with dissimilar stiffness levels at their folds and faces via multi-step photolithography. Subsequent capillary folding of the sheets towards permanently folded target shapes is realized by thermally controlling, simultaneously, the compliance of the sheets and the volume of the deposited droplets. This fabrication method allows us to create millimeter and sub-millimeter polyhedral structures with arbitrary levels of folding, to manufacture permanently folded polymer polyhedra using single-material monolayer sheets, and to produce carbon shapes from these carbon-rich polymer polyhedra through pyrolysis.