Based on the bending-active concept, this paper presents a self-shaping system with bunched carbon fiber-reinforced polymer (CFRP) rods to construct complex curved surfaces, establishing an overall design and construction process. Such component consists of a bunch of slender and easily bendable CFRP rods that are preformed and then bounded by connecting joints. Then, those components form free-form spatial structures. The proposed system offers several advantages: strong designability, low transportation cost, short construction period, polished appearance and low maintenance requirements during service. For component design, to determine the shape of such component, a two-stage mechanical analysis is proposed based on the large deformation theory and finite element analysis (FEA): a form-finding process to determine the deformed component shape through its cross-sections and boundary-load conditions; and a reverse form-finding process to obtain these above-mentioned parameters from a given component shape. The reliability of both methods is verified through in-plane bending tests. A design demonstration of a saddle-shaped curved spatial structure is performed using this method. Overall, the proposed system can guide the actual construction projects of complex curved surfaces with self-shaping bunched CFRP rods.
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