Abstract
Presently, the realization of complex, unconventional designs using efficient modalities is possible due to an increasing interest in interdisciplinary approaches: materials science, mathematics, IT, architecture, etc. Computerized techniques, among which the algorithmic/generative design is the most advanced one, that are associated with the individualized production methods are used for finding solutions for modern spatial forms with an unconventional spatial geometric shape, which are generically called “free-forms”. This work presents the design, realization and testing of a thin-walled metallic structure proposed as a light structural unit. An integrated research approach was proposed that utilized an algorithmic/digital design applied to the curved-crease-folding method with the study (at different length scales) of the metallic material behaviour after folding. An original method was proposed for the digital design and simulations. The specific mechanical behaviour of the metallic material in the elastic−plastic regime was used in this case to improve the structural performances; mechanical and structural tests were realized to analyse the behaviour of the entire structure. The results are useful for enhancing the accuracy of the digital design, the structural simulation programs and the fabrication methods.