Arbitrarily Curved Support Structure via Flat Piece Folding
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Solution Overview
Problem
Constructing support structures with three-dimensional, arbitrarily curved geometries that can bend freely in three mutually orthogonal directions is particularly challenging, especially in architectural applications where torsion around the own axis is required.
Innovation Solution
A method involving digital representation of the desired geometry, approximation with polygonal cross-sections, division into parts, definition of cut-out areas and connection points, folding, and assembly of flat pieces to achieve the desired curved geometry, allowing for simple and error-free production of support structures with any length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional methods are used to construct support structures with three-dimensional arbitrarily curved geometries, then the structures can achieve complex shapes, but the construction becomes particularly difficult and complex
Solution Approach 1:
The support structure is divided into multiple individual components (first support component, second support component, etc.) that can be manufactured separately using flat pieces of material. Each component is then folded along defined fold lines to achieve the required three-dimensional curved geometry. This segmentation allows complex shapes to be constructed from simpler individual elements, reducing overall construction complexity.
Solution Approach 2:
The invention transforms flat two-dimensional pieces of material into three-dimensional curved support structures through folding operations. By defining specific fold lines and folding directions on flat material sheets, the structure achieves arbitrary three-dimensional curvatures while maintaining manufacturing simplicity. This dimensionality change allows complex spatial geometries to be produced from simple planar starting materials.
2Ease of manufacture
If flat pieces of material are folded to achieve three-dimensional curved geometries, then the manufacturing process is simplified, but achieving accurate dimensional precision becomes challenging
Solution Approach 1:
The invention defines fold lines, folding directions, and connection point locations in advance during the design phase. These preliminary definitions ensure that when the flat material is folded and assembled, the resulting support structure achieves the desired dimensional accuracy. The pre-planned geometry and connection points guarantee proper alignment and spatial relationships without requiring complex adjustments during assembly.
Solution Approach 2:
The invention replaces complex mechanical assembly operations with a folding and connection process. Instead of requiring precise mechanical forming operations to create three-dimensional curved geometries, the solution uses defined fold lines that guide the material through simple folding actions. The connection elements then automatically ensure proper positioning and dimensional accuracy through their geometric design.
3Adaptability or versatility
If support structures are designed to bend freely in three mutually orthogonal directions, then architectural versatility is improved, but the constructive solution becomes particularly difficult
Solution Approach 1:
The support structure is designed with multiple fold lines arranged in different orientations, allowing the structure to bend and adapt in three mutually orthogonal directions. The fold lines are positioned and oriented to enable dynamic spatial adjustments while maintaining structural integrity. This dynamic design allows the support structure to achieve various architectural configurations without requiring complex constructive solutions.
Data Source
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AI summary
Method for producing a support structure (1) extending in a three-dimensional, arbitrarily curved geometry (2) from at least one first and one second flat piece of material (3, 4), wherein the geometry (2) has curvatures in three mutually orthogonal directions, comprising the following steps: A. Providing the desired geometry (2) B. Approximating the desired geometry (2) C. Dividing the geometry (2) D. Defining at least one clearance area (10) E. Defining a plurality of connection points (11) arranged on the at least one first and one second part (8, 9) F. Defining bending edges (12) extending between the polygonal cross-sections (5) G. Unfolding the at least one first and one second part (8, 9) H. Cutting at least one first and one second flat piece of material (3, 4) I. Bending J.Connecting the at least one bent first piece of material (13) and the at least one bent second piece of material (14).