Y-zipper: 3D Printing Flexible–Rigid Transition Mechanism for Rapid and Reversible Assembly

We present Y-zipper, a novel three-sided 3D-printed zipper structure that enables three flexible strips to interlock and transform into a rigid rod-like form. Building on this flex–rigid transition mechanism, we further design a specialized slider to achieve rapid and reversible zipping interactions. This slider serves as the basis for three actuation methods—manual, dynamic mechanical, and static mechanical—which enable both remote control and automated closure and release. In addition, Y-zipper provides four motion primitives: straight, bend, coil, and screw, whose combinations extend the flex–rigid transition mechanism to spatial curve structures. To support customization, we develop a computational design tool that automatically generates zipper geometry based on input primitives, unfolds the structure for 3D printing, and embeds both teeth and compliant bridges. Controlled experiments evaluate its mechanical properties, repeatability, and actuation speed, demonstrating robustness and reliability. Finally, we showcase a series of functional prototypes, including a medical wrist brace, a kinetic art installation, and a rapidly deployable tent structure.