Imagine launching a robot into space that starts as a flat structure but later unfolds, reshapes itself, and becomes a bridge, a tunnel, or even part of a future space habitat. It may sound like science fiction, but engineers have now taken a major step toward making this idea a reality.
Researchers from North Carolina State University (NC State) have developed an innovative shape-shifting robot that can transform into more than 1,000 different configurations while using only three active motors. Inspired by the ancient art of origami, this remarkable robot could one day help astronauts build habitats on the Moon, Mars, or other space destinations without requiring heavy construction equipment.
The research, published in the journal Nature Communications, demonstrates how a simple yet intelligent design can make future space missions more efficient, affordable, and flexible.
A Robot That Changes Shape
Unlike traditional robots that are built for a single task, this new robot is designed to transform into many different forms depending on what is needed.
The robot is made from 36 hollow plastic cubes created using 3D printing. These cubes are connected by rotating hinges that allow the structure to fold and unfold in different ways. Some hinges remain fixed with metal pins, while others are powered wirelessly by motors.
What makes this design truly impressive is that the entire structure needs only three active motors to create over 1,000 unique shapes. Normally, robots with many moving parts require a motor for every joint, making them heavier, more expensive, and more likely to fail. By dramatically reducing the number of motors, the researchers created a lightweight and efficient system without sacrificing versatility.
Inspired by Origami and Nature
The idea behind the robot comes from origami, the Japanese art of paper folding. Origami has inspired engineers for years because flat materials can be folded into complex three-dimensional structures.
The researchers also looked to nature for inspiration. Just as muscles contain layers of fibers working together to produce movement, the robot uses a hierarchical design where different sections work together to create large shape changes with only a few powered joints.
Instead of relying on dozens of motors, the robot cleverly distributes movement through its connected cubes. This allows the entire structure to transform while keeping the design simple.
According to the researchers, the goal was to achieve the greatest number of possible shapes using the fewest number of actuators, which are the motors responsible for movement.
More Than 1,000 Possible Shapes
One of the most exciting features of this robot is its incredible flexibility.
During testing, the transformer robot successfully changed into a wide variety of shapes, including:
Bridges
Tunnels
Multi-story structures
Box-like cubes
Flat platforms
Other complex architectural designs
The robot can quickly switch between these different forms depending on the task.
For example, it could begin as a flat structure during launch to save valuable space inside a rocket. Once it reaches the Moon or Mars, it could unfold into a shelter, storage unit, walkway, or support structure.
If mission requirements change later, the same robot could simply transform into another useful shape instead of needing an entirely new machine.
Built for Future Space Missions
Sending equipment into space is extremely expensive. Every kilogram added to a rocket increases launch costs significantly.
Because this robot folds flat before deployment, it occupies much less space than a traditional rigid structure. This compact design could reduce transportation costs while allowing astronauts to carry more equipment.
Once it arrives at its destination, the robot could assemble itself into larger structures.
Researchers believe future versions could help build:
Temporary shelters for astronauts
Living habitats on the Moon or Mars
Storage facilities
Walkways connecting different buildings
Scientific research stations
Emergency protective structures
Even more importantly, these structures could later be taken apart and reassembled into completely different shapes if mission needs change.
It Can Move While Transforming
The robot is not only capable of changing shape—it can also move.
During experiments, researchers showed that it could travel:
Forward
Backward
Sideways
It can also climb inclined surfaces while carrying loads.
Another impressive achievement is its strength. Despite being lightweight and mostly made from plastic, the robot can carry approximately three times its own weight.
This combination of mobility and transformation makes it useful not just as a building structure but also as a robotic assistant capable of transporting equipment in challenging environments.
Why Fewer Motors Matter
One of the biggest engineering challenges in robotics is balancing flexibility with simplicity.
Adding more motors gives robots greater movement, but it also increases:
Weight
Cost
Energy consumption
Mechanical complexity
Risk of failure
The NC State team solved this problem by designing a structure where only a few motors control many different parts.
This approach creates a robot that is easier to operate, lighter to transport, and potentially more reliable during long-duration space missions where repairs are difficult.
Reducing mechanical complexity is especially important in space because maintenance opportunities are limited and replacement parts are not readily available.
The Road Ahead
Although the current prototype is an important milestone, researchers say there is still much work to do.
Future versions will need stronger materials capable of supporting larger loads. Engineers also want to design robots that can transform into very specific objects.
For example, instead of simply forming bridges or tunnels, future robots could transform into:
Vehicles
Construction equipment
Mobile laboratories
Communication towers
Emergency rescue robots
Researchers are also exploring how artificial intelligence could eventually allow these robots to decide the best shape for a particular task without human intervention.
Imagine a robot that automatically transforms into a bridge when it detects an obstacle, then later becomes a shelter when astronauts need protection.
Applications Beyond Space
Although space exploration is the main focus, this technology has exciting possibilities on Earth as well.
Shape-shifting robots could assist in disaster response by quickly creating temporary shelters or bridges after earthquakes and floods.
Military and emergency teams could use them to build portable infrastructure in remote locations.
Construction companies might one day deploy modular robots that change shape depending on the job.
Even warehouses and factories could benefit from robots that adapt their structure for different tasks instead of requiring multiple specialized machines.
A New Era of Modular Robotics
This research represents a major step toward creating robots that are flexible, lightweight, and highly adaptable.
Instead of sending many different machines into space, future missions may only need a collection of modular robots capable of transforming into whatever is required.
By combining origami-inspired engineering, 3D printing, and smart mechanical design, the NC State team has shown that a small number of motors can unlock an enormous number of possibilities.
As humanity prepares for long-term missions to the Moon and Mars, technologies like these could become essential for building safe, sustainable habitats far from Earth.
A robot that begins its journey as a flat sheet and later transforms into homes, bridges, or even vehicles may soon move from the laboratory into the future of space exploration.
Reference: Li, Y., Di Lallo, A., Zhu, J. et al. Adaptive hierarchical origami-based metastructures. Nat Commun 15, 6247 (2024). https://doi.org/10.1038/s41467-024-50497-5
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