AquaFold
A bistable origami water-safety buoy that folds flat and snaps open.
- Year
- 2024
- Category
- Functional Products
- Role
- Independent Designer
- Type
- Master's Studio Project
- Tools
- Fusion 360, KeyShot, 3D Printing, TPU Prototyping, Model Making
- Output
- Bistable folding prototype, one-way valve concept, release mechanism and product visualisation
One-line Definition
A compact self-inflating buoy enabled by a bistable origami structure.
Brief
AquaFold rethinks the swimming buoy as a compact object that can be worn or stored flat before use. It combines a Kresling-inspired bistable body, one-way inflation valve and quick-release cord mechanism. The design aims to improve portability and response speed without sacrificing buoyancy or stability.
Problem
Conventional buoys are often bulky to carry, slow to inflate and awkward to store, which discourages everyday use. In emergencies, delayed deployment and unstable shapes can reduce their effectiveness for older users, beginners and open-water swimmers. Materials must also withstand repeated folding, abrasion and prolonged contact with water.
Research & Insights
Research analysed drowning-risk groups and compared open-cell foam, chemical gas systems, electric pumps and direct one-way inflation. Material studies considered TPU, UHMWPE coatings, polyester connections and printed PLA valve components. Origami precedents were evaluated for compactness, self-support and repeatable deployment.
Design Opportunity
A folding structure could make safety equipment easier to carry before an emergency rather than merely effective after one occurs. Bistability offered a way for the product to remain compact in storage and stable after deployment. A simple manual system also reduced dependence on batteries and disposable gas cartridges.
Concept Development
The buoy folds into a flat fan-like form and is secured at the waist through a rotary tightening mechanism inspired by the BOA system. In an emergency, the user releases the restraint and opens the one-way valve so the structure expands into a buoyant cylinder. High-visibility colour and a grab cord support rapid recognition and handling.
Form Development
The form is generated from repeated triangular folds that create a rhythmic geometric surface when expanded. In the closed state, the layers compress into a compact, wearable profile; in the open state, the same pattern becomes a strong cylindrical volume. Bright orange and dark structural details communicate emergency visibility and durability.
Structure & Prototyping
Kresling geometry was selected over zipper-coupled structures because it offers self-locking behaviour, lower weight and a simpler sealed volume. TPU provides elasticity and waterproofing, while an UHMWPE outer layer improves abrasion resistance. The PLA one-way valve and polyester cord system separate precision components from the flexible body.
Testing & Iteration
Paper and printed models compared fold patterns, stable states and the effect of wall thickness. Reinforcing the fold skeleton improved bending durability by roughly three times while reducing material use and overall weight. Iteration also examined valve sealing, repeated deployment and the balance between flexibility and buoyant volume.
Final Design
The final design combines a foldable TPU body, protective coating, one-way valve, rotary release and polyester pull cord. It stores as a compact object at the waist and expands into a self-supporting buoy for emergency assistance. The structure remains visually legible so users can understand how to release, open and hold it.
Use Scenario
Before entering the water, the swimmer secures the folded buoy at the waist. If fatigue or danger occurs, the user releases the cord, opens the valve and lets the body expand before holding it close for support. The compact form also suits travel, training and seasonal storage.
Outcome
AquaFold demonstrates how geometric behaviour can become the primary mechanism of a safety product. The project connected origami research with material selection, valve design and emergency-use scenarios. Further development would require certified buoyancy testing, long-cycle fatigue testing and manufacturing studies for sealed TPU structures.