Algorithmic Design and Fabrication of Soft Curved-Folding

Abstract This paper introduces an algorithmic method for designing and fabricating soft curved-folded surfaces using minimally stretchable thick panels, validated via the production of a free-form sculpture in fiber cement board. The proposed digital workflow combines crease-aware mesh generation with elastic simulation in Rhinoceros and Grasshopper. The study demonstrates how carefully calibrated constraints and real-time user adjustments enable the shaping of a complex, self-supporting form while minimizing material stretching and ensuring partial developability. A tailored manufacturing process, involving a digitally modeled and 3D-printed mold, facilitates the shaping of fiber cement with soft folds. Although tested on a 160 cm high sculpture, the method is broadly applicable to other foldable sheet goods with similar properties, offering the potential for both architectural and manufacturing applications.