SBIR Phase II: Computer-Aided Design Software for Novel Geometric-Inspired Engineering and Manufacturing

The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase II project is to accelerate the adoption of novel geometric design principles in industrial applications. Over the past two decades there has been significant growth in novel applications of geometric modeling across science and engineering. However, existing computer-aided design (CAD) tools remain limited in their ability to model folded structures. This Phase II project and commercialization effort will address this gap by developing a powerful, user-friendly software system for novel geometric-inspired design. The proposed technology will enhance manufacturing efficiency by enabling 2D fabrication of 3D structures, optimizing material use, and reducing part counts. While the initial target market for commercialization is structural packaging engineering, potential applications span product design, architecture, sheet metal fabrication, medical devices, aerospace, and education. The resulting CAD system will enhance scientific and technological understanding of integrating foldable structures into practical design workflows. This Small Business Innovation Research (SBIR) Phase II project will develop a novel computer-aided design (CAD) software system that applies mathematical insights to support the design of folded structures. The core innovation is a parametric modeling framework that allows users to rapidly construct folded designs, while the underlying geometry kernel manages geometric constraints to ensure successful folding. Phase II research objectives include: (1) developing data structures and design algorithms that underpin the geometry kernel, (2) advancing the CAD system’s parametric design capabilities and (3) validating the system’s usability and performance through structured user studies and beta testing with potential customers. A key focus of the Phase II R&D is curved folding, a powerful yet underexplored technique for designing structurally efficient and visually distinctive forms. The anticipated outcomes include the development of novel geometric modeling techniques for both straight crease and curved creases, as well as the release of an end-to-end CAD system initially focused on packaging design workflows. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.