Tensional twist-folding of sheets into multilayered architectures and scrolled yarns (original) (raw)

Twisting sheets as a strategy to form yarns with nested structure lacks scientific guiding principles but relies on millennia of human experience in making catguts, food packaging, and redeployable fabric wearables. We formulate a tensional twist-folding route to making yarns with prescribed folded, scrolled, and encapsulated architectures by remote boundary loading. By harnessing micro-focus x-ray scanning to noninvasively image the fine internal structure, we show that a twisted sheet follows a surprisingly ordered folding transformation as it self-scrolls to form structured yarns. As a sheet is twisted by a half-turn, we find that the elastic sheet spiral accordion folds with star polygon shapes characterized by Schlafli symbols set by the primary instability. A scalable model incorporating dominant stretching modes with origami kinematics explains not only the observed multilayered structure, torque, and energetics, but also the topological transformation into yarns with prescri...