Metal Blossom: Laser Forming Complex and Freeform Metal Structures Imitating Flower Blooming

TL;DR

This paper introduces a novel laser-forming technique called lasergami, which uses computational origami methods to create complex freeform metal structures inspired by flower blooming, enabling cost-effective and practical manufacturing of intricate metal shapes.

Contribution

It demonstrates for the first time that lasergami can form complex freeform metallic structures using new computational origami methods and optimized laser instructions.

Findings

Successfully formed complex freeform metal structures

Developed a low-cost, practical manufacturing framework

Enabled hobbyists and professionals to adopt the technique

Abstract

For centuries, human civilizations devised metal forming techniques to make tools and items; yet, customized metal forming remains costly and intricate. Laser-forming origami} (lasergami) is a metal forming process where a laser beam cuts and folds a planar metal sheet to form a three-dimensional (3D) shape. Designing foldable structures formable by lasers, however, has long been a trial-and-error practice that requires significant mental effort and hinders the possibility of creating practical structures. This work demonstrates for the first time that lasergami can form a freeform set of metallic structures previously believed to have been impossible to be laser-formed. This technological breakthrough is enabled by new computational origami methods that imitate flower blooming and optimize laser folding instructions. Combined with new ideas that address laser line of sight and minimize fabrication energy, we report a low-cost manufacturing framework that can be readily adopted by hobbyists and professionals alike.