Laser Forming for Complex 3D Folding

Abstract

the underside. At this price point, these processes will enhance the small scale metal fabrication capabilities for a wide range of researchers, educators, and small businesses.

Self‐Folding Metal Origami

“…Based on simple thermal expansion and the resulting plastic stress buildup, laser forming can be performed on a relatively broad material set. Numerous metals have been laser formed such as aluminum, titanium, nickel, stainless and other steels, copper alloys, and nickel‐titanium shape memory alloy . Although rarer, there have been demonstrations in nonmetals such as crystalline semiconductors and glass and ceramics .…”

“…In one early example, steel sheeting was cut and formed into practical parts for a vehicle, including cover plates and a scale model door panel (Figure ) through manual alignment and flipping . Building on this work, other research studies demonstrated the possibility of using a motorized stage for positioning and flipping during the laser cutting and folding process to obtain up and down folds or using the TGM and BM modes together with laser cutting to create complex parts without repositioning the part …”

“…h) laser‐folded copper cube and i) laser‐folded nickel airplane with up and down folds in the same part. Reproduced with permission . Copyright 2017, Wiley‐VCH Verlag GmbH & Co. KGaA, Weinheim.…”

“…This allows up and down folding in the same part using the same laser. Because the TGM and BM modes are based on the type of temperature distribution in the material, it is possible to switch between them by using the laser travel speed . A fast travel speed results in a vertical temperature gradient and upward folding based on TGM, while slowing down the travel speed gives time for the heat to propagate through the thickness leading to BM folding.…”

“…A fast travel speed results in a vertical temperature gradient and upward folding based on TGM, while slowing down the travel speed gives time for the heat to propagate through the thickness leading to BM folding. When combined with laser cutting, laser forming allows complex 3D parts to be rapidly folded directly from metal sheeting (Figure h–i) …”