Learn more about this 2026 Madison Trust Project.
Folding for Strength: Origami-Inspired Slabs for Sustainable Concrete Construction
Presenters
Dr. Steven Woodruff | woodrusr@jmu.edu Assistant Professor, Engineering, College of Integrated Science and Engineering
Abstract
This project explores how origami-inspired folding can reduce the amount of concrete needed for structural slabs, addressing the global concern that suitable sand resources may be depleted by 2050. By using geometric shaping rather than added material to increase strength, the project aims to create lighter, stronger, and more sustainable construction elements. If successful, this approach could open the door to rapid, fold-in- place construction methods that simplify building processes and reduce environmental impact. The research positions JMU at the forefront of creative, sustainable engineering solutions.
Project
Concrete is the most widely used human-made material, yet its environmental burden is significant. The United Nations has warned that natural sand suitable for concrete production may become critically scarce by 2050 (United Nations, 2014; United Nations, 2022). This challenge calls for new approaches that preserve structural performance while using less material. Origami-inspired engineering offers a compelling opportunity to achieve this goal by using geometry to create strength where it is needed most. The project investigates how folded, origami-inspired geometries can enhance the stiffness and load-carrying capacity of thin slabs without adding material. Prior research has shown that curved-crease folds redistribute stiffness across a surface, resulting in more isotropic (i.e., strength in all directions of bending) and efficient load resistance (Woodruff and Filipov, 2020). Similar ideas have been explored at architectural scales, such as the ORICRETE framework for folded concrete structures (Chudoba et al., 2014). However, there is limited experimental data on whether these geometric benefits translate to flat slabs, which are among the most common structural elements worldwide. The central goal of the project is to determine how different folded geometries influence the strength-to-weight ratio of gypsum slabs, which serve as small-scale analogs for reinforced concrete. The work balances sustainability and engineering innovation by asking a simple but important question. Can we replace material consumption with
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geometric intelligence, creating slabs that are stronger because of their shape rather than their mass?
This project builds on successful in-class work from ENGR 314 – Materials and Mechanics, where students designed and tested origami-inspired plates. Many of their designs outperformed traditional flat slabs, demonstrating both feasibility and the strong educational impact of geometric structural design. The proposed project extends this idea into a rigorous research study. The methodology consists of designing, fabricating, and testing 12 different slab geometries. Students will use laser-cut molds to cast gypsum slabs of equal mass but varying crease patterns, including flat, straight-crease, and curved-crease designs. Each geometry will be produced in triplicate to ensure replicability. After a 24-hour curing period, the slabs will undergo three-point bending tests on an Instron machine. This produces load-displacement curves, allowing the research team to quantify stiffness, peak load, and failure modes. A key innovation involves curved-crease forms, which can be difficult to fold in rigid materials. To mitigate this, students will discretize each crease pattern into small, flat facets that fold with minimal actuation force. This reduces strain buildup and increases the reliability of mold construction. The team is supported by a concrete laboratory, a campus MakerSpace for molding fabrication, and lab staff who assist with machining and mechanical testing requirements. The expected outcomes include identifying which geometries maximize strength for a fixed mass, providing concrete evidence that geometric folding can reduce material requirements. Students will also prepare posters and presentations for venues such as the Virginia Academy of Science and undergraduate research symposia. These products strengthen JMU’s culture of undergraduate research and broaden the visibility of sustainable engineering work on campus. Beyond these immediate outcomes, the project creates a pipeline for future research on sustainable construction materials. The findings will inform possible publications in journals such as the ACI Structural Journal or Developments in the Built Environment. Most importantly, this work offers a roadmap for applying advanced geometric concepts to reduce resource consumption in one of the world’s most material-intensive industries.
Benefit to JMU
This project advances several of JMU’s strategic priorities in sustainability, student development, and institutional visibility. By developing a new approach to strengthening concrete slabs through geometry rather than material volume, the project contributes to global sustainability efforts and aligns with CISE’s focus on responsible, efficient engineering. The work also reflects the department’s hands-on approach to education, where students learn through building, testing, and iterating on real structures.
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The project provides meaningful, high-impact research opportunities for undergraduate students. Participants will develop skills in fabrication, experimental design, Python- based data analysis, and research communication. These experiences help students secure competitive internships and offer compelling material for professional portfolios. Because the project trains newcomers, its benefits extend to students who may not otherwise have research access, strengthening equity in undergraduate research participation. For JMU as an institution, this project has the potential to elevate the university’s reputation in sustainable engineering and origami-inspired structural innovation. Demonstrating that JMU students are actively contributing to environmentally responsible construction techniques enhances the university’s public profile and supports recruitment efforts. The project also lays the groundwork for future external support (e.g., through the many NSF sustainability funding opportunities or the American Concrete Institute’s foundation), as the findings could seed subsequent proposals in sustainable materials and structural innovation. The results from this project could be disseminated through a variety of channels. First, undergraduate researchers could share their work through posters at regional conferences, such as the Virginia Academy of Science Undergraduate Research Meeting or the Council on Undergraduate Research Meeting. Additionally, the work could be shared at national conferences, such as the American Society of Civil Engineer’s Engineering Mechanics Institute Meeting or the American Concrete Institute Concrete Convention. Our results would also be shared in peer-reviewed journals, such as Structural Concrete, the International Journal of Concrete Structures and Materials, or the American Concrete Institute Structural Journal. This project additionally opens avenues for collaboration with other researchers in the nation. For example, should the small-scale tests be successful, large-scale testing could be conducted at the University of Michigan (the PI’s alma mater) with Dr. Evgueni Filipov or Virginia Tech with Dr. Alexander Brand, using their strong-wall apparatuses. Furthermore, internal collaboration with concrete researchers at JMU, such as Dr. Daniel Castaneda or Dr. Heather Kirkvold, could expand the project further. Taken together, the project strengthens JMU culturally, academically, and strategically. It offers direct experiential benefit to students, contributes to pressing global sustainability challenges, and positions the university as a creative leader in engineering research and education.
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Projected Budget
Personnel:
$14,892
Travel:
$5,000
Equipment:
$2,000
Supplies and materials:
$1,000
Postage and Printing:
$100
Total:
$22,992
The personnel funding would support two undergraduate research assistants each working 10 hours per week at the Virginia minimum wage of $12.77 per hour over the course of two years. Travel costs account for one conference (e.g., the American Concrete Institute Concrete Convention) attended by the PI and the two research assistants, including conference registration, travel, lodging, and food. The research team will present their results at the conference. Equipment, supplies, and materials will include an apparatus for testing the origami slabs that is compatible with the existing force-deflection machine owned by the Department of Engineering. Additionally, these funds would be used to purchase gypsum cement and materials to fabricate molds. With partial funding of the project, we could achieve a smaller-scale version of the experiments with fewer models and tests. Additionally, the personnel costs could be limited by reducing the number of research assistants to one or using class credits instead of paying students to conduct research. If travel is limited to in-state conferences, the travel expenses could also be reduced. Essentially, the project could be done for much less money, but with less impact.
Project Team
The project team will be led by Dr. Steven Woodruff, an engineering faculty member whose research focuses on origami-inspired structures and sustainable material design. His scholarly work has demonstrated how curved-crease origami redistributes stiffness in thin sheets (Woodruff and Filipov, 2020), establishing a foundation for developing lightweight, strong, and geometry-efficient structures. This background affirms his ability to guide the project from concept to successful experimental validation.
Two undergraduate research assistants will join the team. They will be newcomers to research, and this is an intentional design choice. The project provides a structured,
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hands-on pathway for students to gain experience in mold design, gypsum casting, Instron mechanical testing, Python-based data analysis, experimental planning, and research communication. In Dr. Woodruff’s ENGR 314 – Materials and Mechanics course, students with no prior experience successfully designed and tested origami- inspired plates, many of which outperformed traditional slab geometries. This demonstrates both student capability and the accessibility of the project’s methods. The department supports this project with significant infrastructure. The concrete laboratory will accommodate slab fabrication, while the MakerSpace provides laser cutting for mold creation. Three dedicated lab technicians regularly assist with experimental setup and ensure safe use of the Instron testing system. Together, this team structure combines faculty expertise, eager student researchers, and well supported laboratory facilities, positioning the project for successful execution and meaningful student transformation.
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