As the use of Natural Fiber Reinforced Polymers (NFRPs) become increasingly popular in the built environment, steps in established workflows, including molding and transportation, continue to impose constraints on what is possible in the material's fabrication process. This research builds on previous studies of moldless fiber composites using tailored fiber placement (TFP) as a fabrication method. By integrating compliant folding mechanisms into the flat preform to give shape to the final desired geometry this research replaces all dependencies on molds and formworks during the resin curing process with programmed formal deformations. The desired geometry is digitally simulated from its two-dimensional state into its resultant three-dimensional state and then subsequently structurally analyzed. The flat pack components are material efficient and can be transported flat to the site for their final assembly into their programmed geometry. This form is locked into its bent active state through the use of a simple drawstring that can later be removed to revert the form back into its flat state. This method is demonstrated through the digital fabrication of a stool where flat-packed elements can be deployed into elegant solutions that embody structure, material, and form simultaneously.
Keywords: Natural Fiber Reinforced Polymers (NFRP); bending active structures; flat pack; lightweight structures; moldless fabrication; tailored fibre placement (TFP).