Sunteți pe pagina 1din 275

Origami - Folded Plate Structures

THSE NO 4714 (2010)


PRSENTE LE 2 JUIN 2010
LA FACULT ENVIRONNEMENT NATUREL, ARCHITECTURAL ET CONSTRUIT
LABORATOIRE DE CONSTRUCTION EN BOIS
PROGRAMME DOCTORAL EN STRUCTURES

COLE POLYTECHNIQUE FDRALE DE LAUSANNE


POUR L'OBTENTION DU GRADE DE DOCTEUR S SCIENCES

PAR

Hans Ulrich BURI

accepte sur proposition du jury:


Prof. F. Graf, prsident du jury
Prof. Y. Weinand, directeur de thse
Dr O. Baverel, rapporteur
Prof. P. Heikkinen, rapporteur
Prof. L. Ortelli, rapporteur

Suisse
2010

Abstract.

This research investigates new methods of designing folded plate structures

that can be built with cross-laminated timber panels.


Folded plate structures are attractive to both architects and engineers for their structural, spatial, and plastic qualities.

Thin surfaces can be stiened by a series of folds,

and thus not only cover space, but also act as load bearing elements.

The variation of

light and shadow along the folded faces emphasizes the plasticity of space and envelope.
Folds not only create structural depth, but also perceptual deepness. Folds give rhythm
to space, and variations can be used to express a spatial sequence as well as to modify the
structural strength. Because of this we are convinced that a design method which rapidly
generates and modies folded plate structures is of great interest, and can form the basis
of a productive collaboration between architects and engineers.
In the last fteen years the timber industry has developed new, large size, timber
panels. Composition and dimensions of these panels and the possibility of milling them with
Computer Numerical Controlled machines shows great potential for folded plate structures.
An interdisciplinary team investigates architectural, structural and mathematical aspects of folded plate structures.
The main focus of the architectural portion is the form-nding process which is inspired
by Origami, the Japanese art of paper folding. Based on a simple technique, Origami gives
birth to an astonishing formal richness and variability. Complex geometries are generated
in an economic way and this research aims at transferring these principles to construction
with timber panels. In an intuitive approach, we investigate dierent folding patterns with
paper folding.

The geometry of selected patterns is analyzed with the aim to generate

them in 3D modeling software.


We develop a method that generates doubly-corrugated surfaces by two polygonal lines:
the corrugation prole and the cross section prole.
The corrugation prole denes the characteristics of simply-corrugated surfaces, composed of straight main folds. Simply-corrugated surfaces can be bent by reverse folds. A
series of investigations outlines the parameters which inuence the geometry of reverse
folds.
The cross section prole introduces a secondary corrugation. It outlines the general
shape of the folded plate geometry and denes the bending angles of the reverse folds.
The pattern of folded plate geometries is qualied by the conguration of the two proles. We establish the conditions which allow control of the pattern type and design of
folded plate geometries which respect a given corrugation amplitude.

This allows rapid

repersentation of complex folded plate structures in space as well as unfolded.

A great

variety of forms can be generated. This variability is attractive because it allows the engineer as well as the architect to react on project specic conditions by modifying dierent
parameters of the folded plate structure without distorting its expressive character.
Further on the possibilities of oseting the generated surface are investigated.
inuence of dierent parameters on the oset geometry is shown.

The

Finally a series of prototypes investigates the feasibility of folded plate structures generated with the proposed design method.

Keywords.

Origami, folded plate structures, cross-laminated timber panels, reverse

fold, doubly-corrugated surfaces, corrugation prole, cross section prole

Rsum.

Cette recherche porte sur de nouvelles mthodes de modlisation de struc-

tures plisses en vue de construire ces structures avec des panneaux de bois massif contrecoll.
Par leurs qualits structurelles, spatiales et plastiques, les structures plisses intressent
la fois les architectes et les ingnieurs.
Une srie de plis rigidie une surface mince. Une surface mince plisse peut donc agir
la fois comme lment couvrant et comme lment porteur. Le jeu d'ombres et de lumire
le long des facettes plisses souligne la plasticit de l'espace et de l'enveloppe.

Les plis

ne crent pas uniquement une profondeur structurelle mais aussi une profondeur spatiale
et perceptive.

Ils rythment l'espace.

La variation du rythme de plis est un outil pour

souligner des squences spatiales, mais aussi pour modier la rigidit structurelle. C'est
pourquoi nous sommes convaincus qu'une mthode de modlisation capable de gnrer et
de modier rapidement des structures plisses est d'un grand intrt pour une collaboration
productive entre architectes et ingnieurs.
Les quinze dernires annes, l'industrie du bois a dveloppe des nouveaux panneaux
de bois de grande taille: Les panneaux en bois massif contrecoll. La composition et les
dimensions de ces panneaux, ainsi que la possibilit de les dcouper avec des machines
contrle numrique les rendent trs attractives pour des structures plisses.
Une quipe interdisciplinaire explore les aspects architecturaux, structurels et mathmatiques des structures plisses.
L'objectif de la partie architecturale est la modlisation de structures plisses qui sont
inspires de l'Origami, l'art japonais du pliage de papier. Bas sur une technique simple,
l'Origami donne naissance une tonnante richesse et variabilit formelle. Des gomtries
complexes sont gnres de faon conomique, et cette recherche vise transposer ces
principes la construction avec des panneaux de bois. Lors d'une phase d'explorations intuitives, nous tudions dirents schmas de pliage de papier. Nous analysons la gomtrie
de modles choisis dans le but de les modliser avec un logiciel 3D.
Une mthode qui gnre des surfaces doublement plisses est dveloppe. Ces surfaces
sont dnies par deux lignes polygonales:
transversale.

Le prol d'ondulation et le prol de section

Le prol d'ondulation dnit les caractristiques de surfaces simplement

plisses, composes de plis droits.

A l'aide du pli invers, les plis droits des surfaces

simplement plisses peuvent tre chis.

Une srie d'analyses dcrit les paramtres qui

inuencent la gomtrie du pli invers.


Le prol de section transversale introduit une ondulation secondaire. Il dcrit la forme
gnrale de la gomtrie plisse et dnit les angles de exion des plis inverss.
Les maillages type des gomtries plisses sont conditionns par la conguration des
deux prols. Nous laborons les conditions qui permettent de contrler le type de maillage
et de concevoir des gomtries plisses qui respectent une amplitude d'ondulation choisie.
Cela permet de reprsenter rapidement la gomtrie de structures plisses complexes, dans
l'espace et mise plat. Il est possible de modliser une grande varit de formes. Le prol de

section transversale et le prol d'ondulation peuvent tre adapts aux conditions spciques
d'un projet. Par exemple, l'amplitude des lments de bord du prol d'ondulation peut
tre augmente an de rigidier les bords de la structure plisse.

Cette variabilit est

attrayante car elle permet l'ingnieur, ainsi qu' l'architecte de ragir des conditions
spciques d'un projet en modiant les dirents paramtres de la structure plisse sans
altrer son caractre expressif.
Nous examinons les possibilits de dcaler les surfaces modlises an de leur donner une paisseur. L'inuence de dirents paramtres sur la gomtrie de la surface de
dcalage est montre.
Une srie de prototypes explore la faisabilit des structures plisses gnres par la
mthode de modlisation.

Mots-cls.

Origami, structures plisses, panneaux de bois massif contrecoll, pli in-

vers, surfaces doublement ondules, prol d'ondulation, prol de section transversale

Acknowledgments.

This work became possible with the support and involvement of

people, who shared my enthusiasm, encouraged me, and gave me critical advice.
Here, I would like to express my thanks and gratitude to them:
Professor Yves Weinand who gave me the opportunity to undertake this research and
whose condence in my work let me discover and develop a fascinating subject.
The members of the thesis jury, Dr. Olivier Baverel, Prof. Franz Graf, Prof. Pekka
Heikinnen, and Prof. Luca Ortelli, for their critical examination of the work.
The colleagues of the IBOIS laboratory for their multiple supports and critical advice.
In particular, Franois Demoures and Ivo Stotz for their precious proofreading, Johannes
Natterer, Franois Perrin and Ivo Stotz for their contribution to the building and testing
of prototypes.
Marie Duthilleul, Marie Marcotty and Cline Kobel for their contribution to the drawings of this work.
Peter De Witt for his English proofreading.
Olivier Morand and Nicolas Vaucher for their friendship.
Cosma and Flurin, for their sunshine and unconditional condence.
Anglique Horsten, who encouraged me to undertake this research, actively supported
me along the whole way, and to whom I dedicate this work.

Further I would like to thank the Federal Oce for the Environment FOEN, WOOD 21,
who nancially supported part of this research.

Contents
Abstract

Keywords

Rsum

Mots-cls

Acknowledgments

7
13

Foreword

15

Part 1. Introduction

17

0.1.

Introduction

Chapter 1.

18

Method

19

1.1.

Folding shapes

20

1.2.

Geometry of folds

21

1.3.

Construction of prototypes

21

Chapter 2.
2.1.

Motivation

23

Origami

23

2.1.1.

Japan

23

2.1.2.

Europe

24

2.1.3.

Origami worldwide

25

2.1.4.
2.2.

Origami techniques

26

Folded plate structures

27

2.2.1.

Concrete

27

2.2.2.

Fiber-reinforced composites

28

2.2.3.

Timber

29

2.3.

Timber-derived panels

31

2.3.1.

Solid wood panels

31

2.3.2.

Laminated Veneer Lumber

33

2.3.3.

OSB-panels

34

2.4.

CNC Milling machines

36

2.4.1.

Freedom of movement

36

2.4.2.

Tools

36

2.4.3.

Machine code and control software

37

Chapter 3.

Experimentation with paper craft folding


9

39

10

CONTENTS

3.1.

Diamond pattern

42

3.2.

Herringbone pattern

44

3.3.

Diagonal pattern

46

3.4.

Discussion

48

Part 2. Geometry of folded plate structures

49

Chapter 4.

51

4.1.

Simply-corrugated surfaces

Introduction

51

4.1.1.

Orthogonal projection of folded plate structures

52

4.1.2.

Simple corrugations

54

4.2.

Parallel folds

58

4.2.1.

Corrugation mid-line

59

4.2.2.

Orientation of the folds

60

4.2.3.

Amplitude

61

4.2.4.

Inclination angle and interval

62

4.2.5.

Width of corrugation edges

62

4.3.

Oblique folds

63

4.3.1.

Design by two corrugation proles

63

4.3.2.

Design with a ruled surface

64

4.4.

Discussion

Chapter 5.

Reverse fold

67
69

5.1.

Introduction

69

5.2.

Reverse fold in 2-dimensional space - reection on a line

70

5.3.

Reverse fold in 3-dimensional space - reection about a plane

73

5.4.

Reection - disambiguation

77

5.5.

Reverse fold in orthogonal projection

79

5.5.1.

Reection plane perpendicular to the frontal plane

79

5.5.2.

Reverse fold parallel to the frontal plane

81

5.5.3.

Reverse fold oblique to the frontal plane

97

5.5.4.

Limitations of the bending angle

112

5.5.5.

Amplitude variation

120

5.6.

Discussion

Chapter 6.

Geometries based on reverse fold in orthogonal projection

121
123

6.1.

Macro-form of folded plate geometries

123

6.2.

Cross section prole and pattern types

130

6.2.1.

Side-fold orientation and direction

132

6.2.2.

Cross section prole and basic pattern types

134

6.3.

Limit conditions of cross section and corrugation prole

139

6.3.1.

Convex polygonal cross section proles

139

6.3.2.

Zig-zag cross section prole

156

CONTENTS

6.4.

Discussion

Chapter 7.

Oset

11

182
185

7.1.

Introduction

185

7.2.

Four-edge vertex oset

186

7.2.1.

Oset

186

7.2.2.

Symmetric reverse fold

188

7.2.3.

Asymmetric reverse fold

190

7.3.

Six-edge vertex oset

192

7.3.1.

Symmetric six-edge vertices

192

7.3.2.

Asymmetric six-edge vertices

195

7.4.

Discussion

197

Part 3. Prototypes

199

Chapter 8.

201

Plywood Prototype 01

8.1.

Introduction

201

8.2.

Geometry

202

8.3.

Model

202

8.4.

Joints

202

8.5.

Fabrication and erection

204

8.6.

Loading tests

206

8.7.

Structural design

207

8.8.

Discussion

209

Chapter 9.

Plywood Prototype 02

211

9.1.

Introduction

211

9.2.

Geometry

212

9.3.

Fabrication and erection

214

9.4.

Discussion

216

Chapter 10.

Tests with aluminum plates

219

10.1.

Introduction

219

10.2.

Fabrication

220

10.3.

Discussion

220

Conclusions and outlook

223

10.4.

Conclusions

224

10.5.

Outlook

226

Bibliography

229

Bibliography

229

Appendix

233

12

CONTENTS

Chapter 11.

Illustrations of folded-plate geometries

235

Chapter 12.

The chapel of St.Loup

261

12.1.

Introduction

261

12.2.

Form Generation

262

12.3.

Structure and construction

264

12.3.1.

Structural design

264

12.3.2.

Oset

264

12.3.3.

Fabrication

266

12.3.4.

Construction

266

12.3.5.

Assembly

267

12.3.6.

Gable faades

267

12.4.

Discussion

270

Credits

272

Curriculum vitae

275

13

to Anglique

Foreword
Listen to its tune while crumpling it, feel its resistance, its sharpness, smooth it out
and feel its softness, trace a line, rubber it out, paint it with a soft brush, mark it with a
pen, cut it, tear it, caress it with a pencil .... paper always holds a particular attraction to
me.
Paper is the space of our projections. When we write, draw or paint, we project our
ideas, our imagination, our emotions, onto the paper. Paper is a medium: it reects our
projections.

Like a mirror it restores our reections; not identical but reversed.

This

inversion creates a gap between the gure and its representation which opens up space for
interpretation. The representation has its own reality [

BV91].

The works of architects are projections.


In paper folding, the paper becomes both medium and space.

The projection of an

abstract pattern is folded into space. The space is in-between: in-between the projections
and their medium, in-between the folds. The projections become tangible.
This work is motivated by my fascination for the relationship between representation
of space and space itself. The work is hybrid: In-between drawing and space, in-between
geometry and architecture, in-between project and construction.

It pregures the con-

struction of folded plate structures.


Inne superando l'indagine sull'atto formativo dell'architettura, mi sembra come tutto
riveli che l'architettura, quale fatto, sia

essenzialmente struttura,

intendendo la dizione

Mor52]

struttura nel senso che si assume in logica-matematica cio di complesso di relazioni [

Finally, going beyond the investigation of the formative act of architecture, it seems
that everything reveals that architecture as a fact is

essentially structure,

intending the

word structure in the sense that it is used in a mathematical logic, that is, a complex of
relations [

BM02, Mor52]

15

Part 1

Introduction

0.1. Introduction
This research investigates new methods of designing folded plate structures that can
be built with cross-laminated timber panels.
Folded plate structures are attractive to both architects and engineers for their structural, spatial, and plastic qualities.

Thin surfaces can be stiened by a series of folds,

and thus not only cover space, but also act as load bearing elements.

The variation of

light and shadow along the folded faces emphasizes the plasticity of space and envelope.
Folds not only create structural depth, but also perceptual deepness. Folds give rhythm
to space, and variations can be used to express a spatial sequence as well as to modify the
structural strength. Because of this we are convinced that a design method which rapidly
generates and modies folded plate structures is of great interest, and can form the basis
of a productive collaboration between architects and engineers.
An interdisciplinary team investigates architectural, structural and mathematical aspects of folded plate structures.
The main focus of the architectural portion is the form-nding process which is inspired
by Origami, the Japanese art of paper folding. Based on a simple technique, Origami gives
birth to an astonishing formal richness and variability. Complex geometries are generated
in an economic way and this research aims at transferring these principles to construction
with timber panels.
This thesis is structured in three parts:

Part 1

Presents the working method, the considerations that motivated the research,
and the intuitive form-nding by paper folding.

Part 2

Presents a design method to generate folded plate geometries and discusses the
conditions of application of this method.

Part 3

Presents a series of prototypes based on the proposed design method

An appendix presents examples of geometries, and a rst full-scale building, designed with
the proposed method.

CHAPTER 1

Method
We chose an investigation method close to the architectural design process. Starting
with a wide range research phase we are going to circumscribe the subject in a series
of loops until crystallizing a precise project.

It is important to note that we are not

talking about a linear process even though, for questions of clarity, it is related as such.
We propose to work with three dierent lines of investigation in order to understand the
formal, geometrical and physical aspects of folded plate structures based on origami (see
gure 1.0.1).

Folding

paper is used during a form nding process. Dierent types of folding patterns
are explored in order to discover interesting geometries for architectural and
structural applications.

Analyzing

the chosen geometries in order to understand their properties, with the goal of
proposing a geometric design method that then generates them in 3D modeling
software.

Building

prototypes to investigate the transposition from the geometrical model to the


materialized structure, to show their construction feasibility, and to test their
structural behavior.

Issues and results of each type of investigation enable the comprehension of the other
explorations. For example, questions that arise during the building of prototypes will give
new points of view to the geometrical analysis, which could reveal dierences between
shapes generated by paper folding and by the computerized modeling tool.

Figure 1.0.1. Folding, Analyzing, Building


19

20

1. METHOD

1.1. Folding shapes


The folding of paper, links in a very simple and direct way, intuitive perception, apprehension of geometry and structural behavior. By shaping paper with our hands we see and
feel new forms as well as their strength and elasticity. The folds give paper new shape and
stiness. Paper folding requires manual dexterity and geometric powers of imagination. It
is between craftsmanship and abstract mathematical thinking. By a precise subdivision of
the paper, a two dimensional surface becomes a spatial sculpture. Even though training
and experience makes the transition from the abstract, two dimensional tessellation, to the
folded geometry more predicable, the folding process creates surprises. This is what makes
paper folding challenging and exciting. The geometry of folding obeys rules which restrict
formal expression, but on the other hand create forms that are beyond our imagination.
A folded paper can be manipulated, opened and closed, mainly by translations and
rotations. These manipulations transform the shape of the folded paper. Geometric variations within a given pattern type also modify the folded shape.
The initial position of the research is to discover and understand the possibilities of creating folded plate geometries through playing with paper folding. We consciously advocate
an intuitive approach that builds up on hands-on experience: by folding and manipulating
paper, hands and eyes collaborate in a dialog of spontaneous understanding of the potential
of such forms. Besides the acquisition of knowledge based on handcraft, the advantage of
such a naive approach is the freedom from prejudice and preconception.
On the other hand, this is in contradiction to a scientic approach, that starts with
the state of the art and builds up on reasoning from existing knowledge. An architect is
constantly challenged to evolve within dierent disciplines and a multitude of generally
contradictory constraints.

In such a situation the principles that guide the architect's

project can not be established by pure deterministic reasoning. His conceptual tools are
hybrid, moving in-between the disciplines, unifying subjective perception and analytic
observation.
To be original and authentic, intuitive perception and understanding should precede the
analysis and be established without preconceptions. For this reason we propose to initiate
the research by an intuitive, hand's-on approach and only in a second phase examine the
folded geometries with analytical tools. The inherent disadvantage of such an approach
is to rediscover things that others discovered before.

On the other hand it procures an

original perception which is of rst importance for an architect: see with your own eyes,
touch with your own hands, and feel with your own body.

An architect's reasoning is

inuenced by experience and memory of body, as much as by analytical thinking.


Besides the gain of intuitive knowledge, the goal of this phase of observation is to identify folding patterns with potential to be transposed into folded plate structures. Selection
criteria are:

the suitability of the geometry to shelter spaces


the appropriateness for construction with cross-laminated timber panels
the potential of the pattern for variation

1.3. CONSTRUCTION OF PROTOTYPES

21

the simplicity of the pattern


the aesthetic fascination of the pattern

1.2. Geometry of folds


In an initial phase, regular folding patterns are modeled in a 3D CAD software starting
from a two dimensional tessellation. Each face of the pattern is put in space by a series of
rotations and symmetries. This very onerous process only allows representation of regular
geometries. The nal shape depends on parameters that are controlled by trial and error.
In compensation, the exact representation of the geometry allows precise analysis.
To analyze the geometries we use the classical representations of architectural drawings:
plans and sections. The analysis will show an interesting parallel between the projections
of the geometry onto a plane and completely closed paper folds. Starting from this we will
establish the rules of how to draw folded plate geometries in 2D space. Once the form is
drawn on a plane it can be deployed into 3D space similar to the opening of a folded sheet
of paper. Further analysis will show that the geometry can be dened by two lines.
The need to give a thickness to the two dimensional faces comprising a folded plate
geometry, in order to build them with timber panels, indicates further issues that are
needed to complete the geometrical analysis.

1.3. Construction of prototypes


The goal of the construction of prototypes is to test and show their feasibility. Therefore
the following issues will arise:

How to transpose the material thickness of the timber panels onto the existing
geometry ?

Which is the shape of the panel edges and what kind of connectors can be used
to join the panels ?

How can the panels be manufactured ?


How can the folded plate structures be assembled precisely and rationally ?
What is the structural behavior of the prototypes under load ?
How can the structural behavior of the prototype be calculated ?
Does the measured structural behavior correspond to the calculated behavior ?

The last three issues need close collaboration with a civil engineer. This part of the research
doesn't claim to give denitive answers to these questions but to measure the problems
that will arise. It is a rst step in the direction of the realization of folded plate structures
with timber panels. Engineering research has to explore these questions. However we are
convinced that it is important to anchor this research in a constructive reality. To approach
the construction of prototypes in an intermediate scale will give positive feedback to the
other issues of the research and develop the feasibility of larger scale structures.

CHAPTER 2

Motivation
This research is motivated by four dierent considerations:

Origami

Paper folding allows creation of a great variety of dierent forms based on


simple principles. This research aims at transposing some of these principles to
a form generation tool which allows rapid creation of folded plate geometries
in 3D space.

Folded plate structures

Folded surfaces are an ecient way to simultaneously create struc-

ture and space of a building. Folded plate structures are therefore attractive
to engineers and architects. By the creation of a design method which allows
integration architectural and structural aspects, we intend to foster the collaboration of both professions and thus contribute to high architectural quality.

Timber derived panels

Since the late nineties, the timber industry has produced large size

timber panels for the construction of massive timber walls. This research intends to reveal the potential of these panels for folded plate structures.

CNC milling machines

The timber industry is well equipped with Computer Numerical

Controlled milling machines.

This technique allows milling of large series of

panels where each panel has a dierent geometry. This facilitates the construction of folded plate structures with irregular and changing geometries.

2.1. Origami
In nature the principle of folding is widely dispersed: a large number of plant leaves and
insect wings deploy and stabilize thin surfaces with the help of folds. Human folding probably began with fabric and paper, thin and exible materials humans fabricate themselves.
Folding seems simple and evident so that it is likely that it developed simultaneously in
dierent geographical locations.

2.1.1. Japan.

Paper was invented in the

fabrication came to Japan in the

XII

II

century in China and the secret of its

century. It was a very rare and precious material

and in the beginning it was mainly used for religious purposes and ritual acts. Buddhist
monks painted their prayers on paper. Immaculate white paper is like a universe at its
beginning, a primeval material; everything is possible and the creation can take any form.
In the Shinto religion, paper embodies the divine nature and folded paper materializes its
presence. Kami, the Japanese word for paper, has a homonym that signies the Shinto
divinity's. Their very diverse nature inuences all aspects of Japanese everyday life. Paper
becomes an important symbol, accompanying the dierent rituals of the Japanese.
23

24

2. MOTIVATION

Paper is also used for very sophisticated wrappings which are often considered more
precious than their content. On their war campaigns the Samurai took with them talismen
made of folded paper. The way they were folded indicated the social position of the owner.
Rules of folding and wrapping are complex and express the taste for sophistication of
Japanese society.
Until the

IXX

century paper was a luxury good which was reserved for the aristocracy.

Only industrial production made paper a democratic consumer item. But also in everyday
households paper is mainly used for rituals and folded as a talisman or folded into boxes
and envelopes to conserve precious goods.
The oldest publication about Origami,

Senbazura Orikata

(see gure 2.1.1), was pub-

lished in 1797. It is an instruction to fold a thousand cranes. The crane is a talisman and
folding a thousand cranes cures disease. A memorial in Hiroshima commemorates a young
girl suering from radiation. She was folding cranes in the hope of convalescing.
The art of ritual origami folding is transmitted from one generation to another. The
folding of the complex gures demands strong concentration and a successfully folded gure
procures satisfaction and relaxation. The success of Origami in Japanese society is based
on cultural aspects but also on the pleasure of play.
The term Origami was invented only in 1880:
paper [

Vas05].

2.1.2. Europe.

Ori

signies to fold and

Kami

signies

Also in Europe dierent sources show the presence of folding tech-

niques. In the XII century the Moors imported paper folding to Spain [

Eng89].

As the

tessellated oors of their mosques and palaces the foldings were abstract and geometric. In
Spain there is still a strong tradition of paper folding and the Pajarita, a geometric gure
of a bird, recalls the inuence of the Moors.

Figure 2.1.1.

Senbazura Orikata [Eng89]

2.1. ORIGAMI

25

In the XVII century publications about the rules of conduct at table show various
illustrations of folded napkins (see gure 2.1.2).

The shapes are abstract and gurative

and some of the foldings are highly sophisticated.


Textile craftsmen produced sophisticated molds out of cardboard to fold fabrics that
are still applied in some workshops [
In the XIX century

Tre08].

Friederich Froebel, the founder of the Kindergarten, developed his

pedagogical tools. He proposed to initiate the learning process of his pupils by stimulating
their curiosity with games and handcraft:
of geometry and harmony.

by folding paper the children discover rules

The objective was to foster their sense of proportion and

accurateness. The international success of the Kindergarten spread the folding exercises
worldwide. Even in Japan folding was discovered in a new form.
Between 1928 and 1933

Bauhaus.

As was

Froebel

Joseph Albers

was the head of the Preparation Course at the

he was convinced that the learning process stimulated by active,

hands on experience is much more ecient than theoretical courses [

Alb52].

He incited

his students to investigate dierent materials with their inherent constructive and formal
logic. Working methods and tools were reduced to the most simple applications. One of his
favorite materials for such exercise was paper. His students discovered various interesting
forms and folding techniques (see gure 2.1.3).

2.1.3. Origami worldwide.


of the Japanese artist

At the end of the fties, the success of two expositions

Aikira Yoshiwazawa

attraction for Origami worldwide.

in Amsterdam and New York, diused the

People were fascinated by Origami and rapidly new

folding techniques and gures were developed. Mathematicians, engineers, architects, designers and biologists investigated Origami and its potential applications to other domains

SF00, SS01], new techniques to fold maps [Miu02], aluminum cans [INI 92], air bags [Cip01] and stents for
surgery[YK03].
and disciplines. They invented foldable solar sails for satellites [

Har57]

Figure 2.1.2. Napkin foldings from the Trincir-Book [

26

2. MOTIVATION

2.1.4. Origami techniques.

Origami is now a very far-reaching area with a variety

of folding techniques and a seemingly unlimited number of fold patterns. Basically, we can
distinguish three dierent kinds of origami.
2.1.4.1.

Classic Origami.

The classic origami mainly deals with gurative depictions

of animals, humans, plants and objects.

The gures are strongly simplied and almost

always two dimensional. They start from a square sheet of paper and are generated only
by folding, without scissors and glue. There is a selection of basic patterns which are used
as starting points for the dierent gures. Originally Origami was an art which sought to
draw the character of a gure by allusions using the least resources possible. The skill is
not to create a perfect replica of a natural model by complex folds, but rather to sketch
the suggestion of a gure. Over the past 50 years, the basic forms and techniques were
well developed and today very realistic gures are being folded.
2.1.4.2.

Modular Origami.

In contrast to gurative origami, modular origami deals

exclusively with geometric solids. Primarily polyhedrons are folded but also spatial lattice structures, or representations of molecules. The geometrical gures are composed of
individual building blocks, which are stuck together.
2.1.4.3.

Origami Tessellations.

This kind of Origami is also purely geometric.

The

starting point is a two dimensional, geometric pattern, known as tiling or tessellation,


which is recorded on the paper and folded.

The pattern is transformed by the folding

process. Some tessellations remain two dimensional but others become three dimensional
and the folded surface gets a certain stiness. Again, the variety of shapes is very large.
Some of the basic patterns are particularly interesting in their spatial development and
therefore deserve our special attention.
For the design of folded plate structures from timber-derived panels only folding patterns which include both a spatial, as well as a load-bearing eect, shall be of interest.

Figure 2.1.3.

Josef Albers

FF99]

commenting the work of his students [

2.2. FOLDED PLATE STRUCTURES

27

Although many of the spatial folds have evolved from traditional gurative origami, we
will focus in this work on the area of modular Origami and especially on tessellations.

2.2. Folded plate structures


Folded plate structures attract both architects and engineers for their structural, spatial
and plastic qualities. Thin surfaces can be stiened by a series of folds and thus not only
cover space but also act as load bearing elements.

The variation of light and shadow

underlines the plasticity of space and envelope, and folds create not only a structural but
also a perceptual deepness. Folds give rhythm to the space and variations can be used to
underline a spatial sequence but also to modify the structural strength.
A thin horizontal surface can cover a large span but will bend under its dead weight.
The folds give the surface the resistance to support loads. Each inclined face of the folded
surface acts as a beam and is horizontally supported by the adjoining face.

If the load

gets too heavy the folds will open up and the surface will bend. Therefore the edges of the
corrugated surface have to be reinforced by bulkheads, tie bars or the foundations in order

Sie60] (see gure 2.2.1).

to prevent the opening of the folds [

It is interesting to note that the development of folded plate structures is closely related
to new building materials. Their implementation requires new construction methods and
oers new structural possibilities.

Concrete and ber reinforced composites essentially

stimulated the development of folded plate structures.

2.2.1. Concrete.

The challenge of large scale concrete shells is to diminish their

dead weight and to make them very thin. To avoid the buckling of the shell, its inertia

a)

b)

c)

d)

Figure 2.2.1. The structural behavior of thin corrugated surfaces [

Sie60]

28

2. MOTIVATION

a)

c)

b)

Nervi [Hux60] b) UNESCO


Nervi [Jon62] c) St.Johns Abbey by Breuer

Figure 2.2.2. a) Piscina dell Accademia by

Congress Hall by
and

Breuer

Nervi [Jon62]

and

has to be augmented and this can be eectively done by a corrugation of the surface
[

Tor61].

The rst generation of folded plate structures has a simple, one directional

corrugation, following a given form and is composed of repetitive elements. The principle
bearing capacity of the structure is achieved by its general shape which conducts the loads
naturally to the ground. The corrugation of the surface allows reduction of the material
thickness and the weight of the structure.
eciency,
surface.

In his research for material and structural

Pier Luigi Nervi renes the principle of vaults corrugated by an undulating


In the Piscina dell' Accademia Navale di Livorno (1947-49) a barrel vault is

supported by inclined pillars (see gure 2.2.2 a)). The surface of the vault is structured
by a ne undulation with small amplitude which increases the impression of thinness and
fragility of the vault. The

Palazzo delle Esposizioni

in Torino (1948-50) is based on the

same principle, but has a much larger span and proportionally the height of the vault is
lowered . The undulating surface is perforated by rectangular openings for natural lighting.
The prefabricated elements composing the vaults are almost dematerialized.

They are

transversely stiened by bulkheads.


In a second phase, structures composed of plane elements are developed and the inherent structural and formal logic of folded plate geometries becomes more expressive. Two

Pier Luigi Nervi and Marcel Breuer (Unesco Congress Hall, Paris, 1953-57 and
St.Johns Abbey, Collegeville 1953-1961) illustrate the principle: corrugated surfaces with
projects of

plane faces are joined to form a rigid frame (see gure 2.2.2 b) and c)). Dimensions and
presence of the folds are emphasized and characterize the architectural expression of the
building.
Most of the folded plate concrete structures have a simple geometry based on parallel
or inversely oblique folds.
which are not realized[

Some sketches show projects with more complex geometries

Sie60, Mor52, Leb80].

2.2.2. Fiber-reinforced composites.

It is only in relation to new composite ma-

terials like ber reinforced plastic, that systematic research on folded plate geometries
started.

Z.S. Makowski

founded the Structural Plastics Research Unit at the University

of Surrey, Guilford, England.

They investigated, among others, folded plate structures

Voi07]

based on anti-prisms which are developable in a continuous surface [

(see gure

2.2. FOLDED PLATE STRUCTURES

a)

b)

29

c)

Huy72] b) Anti-prismatic foldMakowski [Huy72] c) Sulfur factory by

Figure 2.2.3. a) Rectangular anti-prism [

ing structure by

Piano [Huy72]
2.2.3).
lands [

Huybers

Benjamin

and

developed the geometry of anti-prisms at the university of Delft, Nether-

Huy72, HvdE89, Huy99] (see gure 2.2.3 a) and b)).

He created a construction

system for composite materials based on the tetrahedron as basic structural unit.
deepens the study of anti-prismatic structures, initiated by

Huybers

der to apply them to folded plate structures built with cardboard [


parallel, the architects

Ouarmby

and

and

Makowsky, in or-

Sed75a, Sed75b].

In

Piano rst realized ber-glass buildings based on the

new geometries. Inspired by the shelter for migrant farm workers in California [

Quarmby

Sedlak

HVR70],
Qua74].

experimented with dierent folding patterns on cardboard prototypes [

The mobile shelter for a sulfur factory and the structure for a carpenter workshop by

Piano

are regular anti-prismatic structures built with a single base element: a diamond folded

Zod73] (see gure 2.2.3 c)).

along its diagonal [

The research with composites is strongly application orientated: basic knowledge for
construction is not obtained by theoretical and conceptual deduction, but by direct investigation on prototypes [

Voi07].

In these projects it is the geometry of the folds that

shapes the general building form. For economic reasons the buildings are composed of a
large number of identical, prefabricated elements.

2.2.3. Timber. Siegel

mentions that timber could be an interesting material for

folded plate structures but the diculty in producing large timber panels prevents their
construction with this material [

Sie60].

Nevertheless a series of folded plate timber struc-

Lei04].

tures has been built, mainly in beginning of the sixties [

They were realized with

glue laminated timber, plywood or layers of diagonal planks which were glued and nailed
to form a plate. Most of the plates are composed of a framework planked on one or both
sides with the above mentioned materials. The span of the structures is

10 m

to

25 m

The geometries are very simple and either composed of parallel or concentric folds. The
student hostel

Anette Kahn

in Tbingen, Germany (1963) is an interesting exception: the

60 mm-thick plates are


10.5 m (see gure 2.2.4 a)).

roof of the central hall is a series of inversely oblique folds. The


composed of three layers of glued boards and cover a span of

At the fold-edge the plates overlap and are glued together. The joint is reinforced by folded

Lei04].

steel plates which are nailed on the outside of the timber panels [

30

2. MOTIVATION

a)

b)
Figure 2.2.4. a) Anette Kahn Wohnheim [

Tannhausen [Jac05]

Lei04]

b)

rehearsal room of

After an experimental phase in the sixties, folded plate structures in timber are rare.
It is the development of new timber-derived products that revived interest in this structural principle. In 1998 the timber manufacturer
folded plate roof. The span is
work planked with the new
[

Kle98].

by

44 m

built a large warehouse with a

, and the plates are composed of a rectangular frame-

K1 Multiplan

panels which have a maximum size of

2 24 m

rehearsal room of Tannhausen

designed

A particularly interesting building is the

Regina Schineis

Binder

(2002) (see gure 2.2.4 b)). Walls and roof are corrugated surfaces.

The corrugation follows the form of the building and is not reversed at the building's edge.
Structurally it is a series of two hinged-frames with a V-shape. Structure, shape and interior cladding are formed by glue-laminated timber panels which makes the building very

Jac05].

economic [

Folded plate structures simultaneously dene space and structure, which puts them at
the interface of architectural and engineering interests. By their simplicity, they attract
a great fascination. To achieve this simplicity and integrate architectural, structural and
construction constraints, both professions have to work in close collaboration. The key to
this collaboration is the manipulation of the folded plate geometry. Even though knowledge
about folded plate geometries exists, their design is laborious and restricted to some specic
geometries.

It is the goal of this research to provide a tool for the generation of folded

plate geometries and to open up the range of possibilities.

2.3. TIMBER-DERIVED PANELS

31

2.3. Timber-derived panels


As early as 1890 panels made out of timber-derived products were industrially produced

CB97].

The goal was to be independent of the limited dimensions of grown timber and

to dispose of a homogeneous material whose physical and mechanical properties are not
aected by growth-related aws. Plywood panels are made of crossed veneer layers that
are glued together. One great advantage of plywood is its dimensional and deformation
stability: changing the grain orientation of the veneers from layer to layer by 90 prevents
tangential and radial swelling and shrinking. Plywood has been a great success and plates
were used in such very diverse areas as: housing construction, shipbuilding, aircraft, etc...
A wide variety of timber-derived products has been developed since then. All products
are based on the principle of breaking down and reassembling the raw material wood.
The degree of decomposition aects the quality of the product. The load-bearing capacity
decreases with the degree of decomposition and the homogeneity of the material increases.
The deformation stability depends to a large extent on the composition of the panels.

DN02]:

Timber-derived products can be classied in function of their texture [

Solid wood
Veneered materials
Chip materials
Fiber materials
Composites materials

The production optimization, the development of various glues, as well as the development
of materials that meet specic needs, led to a very wide range of products.
Several timber-derived panels are large sized and suitable for structural applications.
They can be classied into three types:

solid wood panels


laminated veneer panels
OSB panels (oriented strand board).

2.3.1. Solid wood panels.

Solid wood panels are made of planks.

Depending on

size and disposition of the planks we can distinguish three types of solid wood (see gure
2.3.1):

layered panels
cross-laminated timber panels
block board panels

2.3.1.1.

Layered panels.

These panels consist of three or ve layers.

The maximum

length of the plates is 5 to 6 m, which corresponds to the maximal length of a plank that
is not glue-joined. The width of the plates varies between 2 and 2.5 m and the thickness
from 15 to 75 mm. The thickness of the lamellas is between 6 and 49 mm. The lamellas
of the middle layer are generally thicker than those of the exterior layers.
deformations of the panels the layers are glued together crosswise.

To prevent

The lamellas of the

exterior layers have a grain orientation parallel to the long side of the panel. All lamellas

32

2. MOTIVATION

are glued to both, the wide and the narrow side. The strength and rigidity of the panels are
similar to that of sawn timber. A large number of manufacturers produce layered panels
[

Sch04].

2.3.1.2.

Cross-laminated timber panels.

The dimensions of cross-laminated timber pan-

els are larger than those of layered-panels: Their maximum size is 24 m long, 4.8 m wide
and 0.5 m thickness (see gure 2.3.2). The number of cross-laminated layers is odd, so that
the planks of the two outer layers are parallel. Generally the dierent layers are glued, but
two manufacturers connect them with aluminum nails or wood dowels.
Most panels are made of side cuts (see gure 2.3.2). Because of their strong deformation
these planks, situated on the edge of the log are not estimated by the saw mill industry.
This disadvantage is not important in cross-laminated panels. Indeed the deformation of
the planks is blocked by the crosswise disposition of the glued layers. The use of side cuts
is even advantageous because the peripheral bers of the tree have better strength values
than those in the center.

Commonly used wood species are spruce, European redwood,

larch, silver r and Douglas r.


The width of the planks varies between 80 and 240 mm, and the thickness between 10
and 35 mm. A ratio of width to thickness which is greater than 1:4 is recommended. The
strength class of the planks used in the various layers can be chosen so that it corresponds
to the subsequent loads. Lengthwise the planks are joined with glued nger joints. As for
glulam the strength of the nger joint must be 5N/mm2 higher than the strength class of
the planks. The nger-jointing of adjacent boards must be shifted and maintain a minimal
distance.
Generally, the planks of the layers oriented parallel to the long side of the panel are
laterally glued. In transverse layers a gap of several millimeters between the boards can

3 and 5 layer panel

cross laminated timber panel

block panel

Figure 2.3.1. Typical cross sections of solid wood panels [

BW07]

2.3. TIMBER-DERIVED PANELS

33

usually be observed. The layers are glued together on their whole surface, which leads to
a quasi-rigid compound [

Sch04, DN02].

There are wide variations in the dimensions of the manufactured plates (see gure 2.3.4).
For planning and execution, this is a diculty, because the products are not compatible
with each other and thus the nal design must be tailored to a particular product. The
maximum size of the panels depends on production and transport conditions. Some types
of plates can be manufactured slightly curved; thereby the thickness of the board must be
adjusted to the curvature radius. Normally, the exterior layer of the panel has industrial
quality, but it can be adapted to specic needs. Most manufacturers oer to execute the
outer board layers in a dierent species.
2.3.1.3.

Block panels.

These panels are based on glue-laminated timber technology.

Boards are glued together by means of a block press to a large cross-section (see gure
2.3.3). Adjacent boards are glued together on their small side. Thereafter, the laminated
block is split parallel to the pressing direction in arbitrarily thick plates.

These single

layered panels are planed and then glued crosswise to a multilayer panel.

Because the

boards are glued on all sides, Block panels have particularly good strength properties and
good windproofness [

DN02].

2.3.2. Laminated Veneer Lumber.


1970.

Laminated veneer lumber has developed since

It is the rst in a series of "Engineered Wood Products" which were developed

for use in structural engineering and were made of three millimeter thick peeled veneer.
After the drying and sorting, the veneers are layered and hot glued. The veneers overlap
at the joints. The overlapping joints of the dierent layers have to maintain a minimum
distance in order to minimize the strength reduction of the panel due to the interruption
of the layers. The width of the panels is due to production constraints. The panels can

normally tensile strength,


modulus of elasticity
and density
increase at the edge of the tree

sidecuts

maincuts

longitudinal layer
glued finger joint

transversal layer

leng

th of

thickness of the panel


42-500mm

the p

anel

+/- 1

6m (m

ax. 2

4 m)

f the
width o

panel

+/- 3m

(max.

4,8m)

Figure 2.3.2. Cross Laminated Timber panels (CLT)[

Sch04]

34

2. MOTIVATION

be manufactured in any length, so this is ultimately limited by the transport conditions.


In standard panels, the grain of all veneers is oriented along the panel. Crosswise layered

DN02].

veneers are used for panels that are loaded in both directions of the surface[

2.3.3. OSB-panels.

Raw material of OSB are approximately 300 mm long at strands,

which are directly deburred from round wood. The strands are parallel and perpendicular
to the long side of the panel.

The quality of the panels can be determined by the ori-

entation and the density of the strands. Four grades are distinguished corresponding to
dierent applications. OSB panels of type 4 are high-load-bearing panels for use in humid

AG05].

environments [

OSB panels have a high percentage of glue and act as a vapor

barrier. Magnum Board and Leno Strand are made of several, glued layers of OSB type 4.
The joints of the panels overlap. The mechanical properties of multi-layered OSB panels
are less favorable than those of laminated veneer lumber or solid wood panels. But they
have a high density which makes them interesting for acoustic applications.
Large size timber panels create new opportunities for architectural and structural design. In a publicity for plywood

Frank Loyd Wright

claimed:

CB97]

To me plywood oers a new lead into a fascinating realm of form [

The goal of this research is to reveal the potential of new timber-derived products for folded
plate structures.

CB97]

Figure 2.3.3. Block panel[

2.3. TIMBER-DERIVED PANELS

Figure 2.3.4. Size of timber derived panels [

35

BW07]

36

2. MOTIVATION

2.4. CNC Milling machines


At present, a large number of Computer Numerical Controlled milling machines are on
the market. They can be distinguished by the following criteria:

Freedom of movement
Cutting tools
Machine code and control software

2.4.1. Freedom of movement.

The freedom of movement primarily depends on the

number of axes and secondarily on their amplitude.


A machine with three axes of freedom can move in two directions in the plane (x/y) and
in the vertical direction (z) (see gure 2.4.1 a)). Usually the range of motion in the plane
is greater than in the vertical direction. Obliquely downward sloping cuts or excavations
of the edge of the panel cannot be executed with a 3-axis machine. This requires a 5-axis
machine which allows a rotation of the tool head around a horizontal and a vertical axis.
With such a machine, a large number of cuts are possible (see gure 2.4.1 b)).
The range of motion of each axis determines the size of the work pieces which can
be cut. To mill large panels a gantry system is necessary. The gantry moves on rails in
the longitudinal direction.

The tool head moves transversely along the gantry and can

also move vertically. With a ve-axis machine rotational movements of the tool head are
possible. The range of movement of large gantry systems varies between 35 and 50m in
length (Y), 3.5 up to 5m in width (X) and 0.48 to 1.2 m in height (Z).

2.4.2. Tools.

Saw blades, Chain saws, drills, milling cutters or other tools can be

mounted on the tool head (see gure 2.4.2). An appropriate tool is chosen in function of
the geometry of the cut and the degree of nish. The machine can change a certain number
of tools automatically. Which tool can be connected and how many tools can be changed
automatically determines the scope of the machine. In function of the type of workpieces
to be milled, the carpenter equips his machine with specic sets of tools.

a)

b)

Figure 2.4.1. a) 3-axis movement, undercuts can not be milled b) 5-axis

Kol03]

movement [

2.4. CNC MILLING MACHINES

2.4.3. Machine code and control software.

37

Each machine has a code that controls

movement and speed of the machine. To program the machine with the code, movements,
type and speed of tools have to be determined in function of the geometry of the work piece.
These features are programmed in specic software which then translates the commands
into the machine code. To guarantee a correct data transmission from the design software
to the tool programming software, the geometry must be properly dened and the two
types of softwares must have compatible data formats.
Because of the relative complex geometry of traditional framework, carpenters have
been equipped with dierent kinds of CNC milling machines for a long time, and have
experience and knowledge in using them. To mill panels for folded plate structures a large
size gantry machine is needed.

Several panel manufacturers also possess gantry milling

machines. They produce and mill the panels, and directly deliver them to the construction
site where they are assembled.
The use of CNC milling machines allows manufacturers to produce work pieces with
complex geometries and without need of false work. A large number of pieces with dierent
geometry can be rapidly produced.

Figure 2.4.2. CNC tools a) Chain saw b) Milling cutter

Hun05]

blade [

c) circular saw

CHAPTER 3

Experimentation with paper craft folding


We used two dierent methods to fold paper:

By folding the paper directly without sketching a two dimensional pattern.


By drawing a pattern on the paper and experiencing if and how it could be folded in three
dimensions.
The

folding method

is close to classical Origami. No lines or measurements are used. The

paper lies on a plane surface and is folded 180 to make the crease. Thereby the paper
always passes by a two dimensional, completely folded state. It can then be opened up to
form a three dimensional polyhedral surface. The folding method generally allows good
control of the three dimensional shape.

In a rst step the paper is folded in a series of

parallel or oblique folds that run through the whole length of the paper. When opened up,
these folds form a simply-corrugated surface with alternating mountain and valley folds
(see chapter 4).

Closed, they form a longitudinal strip, which is then folded cross-ways

to the longitudinal axis of the strip.

The strip is bent into a polygonal gure.

When

opened again, the paper is marked by a pattern of creases. It can be folded into a three
dimensional form by assigning the right oreintation to each fold: mountain or valley fold.
The bending of a straight fold is one of the basic techniques of Origami and called
reverse fold [

Eng89]

(see gure 3.0.1).

creases, cross ways to the main fold.

A straight mountain fold is bent by two side

The side folds and the main fold intersect at the

inection point where the main fold is reversed from mountain to valley fold. The more
acute the angle between the side folds, the bigger the angle between the two edges of the
main fold (see chapter 5).

a)

b)
Figure 3.0.1.

Eng89] b) reverse folds with

a) Folding the reverse fold [

dierent side fold angles


39

40

3. EXPERIMENTATION WITH PAPER CRAFT FOLDING

The control of shape with the

drawing method

is more arbitrary, but it allows folding

of shapes which cannot be completely folded into at, two dimensional gures.

To be

foldable, the vertices of a pattern have to consist of six or four edges. Typically we use the
drawing method to investigate variations of patterns discovered with the folding method.
It is also useful for all patterns which are not based on straight folds that run through the
whole length of the paper, like reticulated patterns or some type of radial patterns.
During our investigations we often combined both methods (see gure 3.0.2).
We nally decided to choose three patterns which we considered particularly interesting
for folded plate structures built with timber panels:

Diamond pattern
Herringbone pattern
Diagonal pattern

All of these patterns have been used in others contexts before. Particularly the students
of

Josef Albers

and those of

Frank Zeier

at the school of ne arts in Zurich, investigated

Con89, Alb52, Zei93].

these patterns in their academic exercises. [

3. EXPERIMENTATION WITH PAPER CRAFT FOLDING

Figure 3.0.2.

Examples of paper folding

41

42

3. EXPERIMENTATION WITH PAPER CRAFT FOLDING

3.1. Diamond pattern


The basic gure of this pattern is a diamond folded along one of its diagonals (see gure 3.1.1 a) and 3.1.2). In diamond patterns all diagonals are folded as valley folds and the
edges as mountain folds. If the pattern is composed of congruent diamonds the curvature
of the folded pattern approaches a segment of a circle. If the diamonds are distorted to kite
shapes the curvature changes. The curvature depends on the angle between the diamond
edges: The more acute the angle, the atter curvature. The pattern can also be varied by
splitting the diamond or kite shape and stretching it along the folded diagonal. The result
is a hexagonal pattern formed by symmetrical trapezoids (see gure 3.1.1 b)).
This pattern can be obtained by folding a series of parallel folds which are the bent by
side folds (see chapter 6). The straight main folds are the diagonals of the diamond and
the side folds are the edges. In those patterns the angles between side folds and main folds
are symmetrical about the diagonal of the basic gure, and the diagonals form a straight
line in the developed surface .
With the second method one can design patterns where the basic gures are not symmetrical about their diagonal or where the diagonals of the basic gures are not straight
lines. These patterns cannot necessarily be completely at folded. With the same method
radial patterns can be designed.
The general form of the folded patterns are cylinder surfaces. They can be deformed
by rotation around an axis perpendicular to the cylinder and thus present doubly-curved
surfaces. These rotations change the opening angle between the faces of the basic gure
which is constant in cylinder surfaces. When a gure with hexagonal pattern is deformed,
the faces don't stay planar.

a)

b)

mountain folds
valley folds
Figure 3.1.1. a) diamond pattern b) hexagonal pattern

This pattern is also named

Yoshimura pattern

after a Japanese scientist who observed

that thin walled cylinders show this kind of buckling pattern under axial compression
[

HA05].

It is interesting to note that the buckled cylinders after a rst failure are strength-

ened by the buckling pattern. This property has been used to design cans with thin aluminum sheets based on the Yoshimura pattern [
be approximated by this pattern [

Miu70].

INI+ 92].

Miura showed that curves can

3.1. DIAMOND PATTERN

Figure 3.1.2. Diamond patterns

43

44

3. EXPERIMENTATION WITH PAPER CRAFT FOLDING

3.2. Herringbone pattern


The basic gure of the herringbone pattern is a mirrored parallelogram (see gure 3.2.1 and 3.2.2).
In this pattern the main folds and side folds are alternatively mountain and valley folds. If
the pattern is composed of parallelograms, the extension of the folded pattern is straight.
If the parallelogram becomes a trapezoid, with both legs inclined in the same direction,
the extension is curved. The dierence of inclination between the legs of the trapezoid determines the curvature of the pattern. If one of the bases (parallel sides) of the trapezoid
is reduced to a point, the pattern is composed of symmetrical triangles that form a dart.
Just as the diamond pattern, the herringbone pattern, can be folded with a series of
reverse folds. The main folds are the bases of the trapezoid, and the side folds the legs.
The angles between side folds and main folds are symmetrical about the main fold, and the
pattern can be varied by the drawing method which also allows design of radial patterns.
Again the general form is a cylinder surface which can be deformed by rotation. The
majority of the deformed patterns consist of non-planar faces because Herringbone patterns
are mainly composed of quadrilaterals.

mountain folds
valley folds
Figure 3.2.1.

Herringbone pattern

Herringbone patterns have been used to design complex napkin foldings. Due to their
doubly zig-zag corrugation they extend in two directions when unfolding . This capacity
has been used to build solar sails for satellites that could be packed in compact way

Miu89].

and once unfolded, have maximum extension [

Ori

The pattern is also called

Miura

after the researcher who built the solar sails and proposed other applications for the

Hob93]and Kling
shows that the folded pattern can be obtained by two corrugation lines [Kli05].
pattern.

Hoberman

describes the possibility of folding curved patterns [

3.2. HERRINGBONE PATTERN

Figure 3.2.2. Herringbone patterns

45

46

3. EXPERIMENTATION WITH PAPER CRAFT FOLDING

3.3. Diagonal pattern


The basic gure is a parallelogram or a trapezoid folded along one of its diagonals
(see gure 3.3.1 and 3.3.2). Contrary to the diamond pattern the basic gure is not symmetrical about a line but symmetrical about a point. In comparison with the herringbone
pattern, the basic gure is not symmetrical about one of the bases of the trapezoid. As
in the diamond pattern all the diagonals of the trapezoid are folded as valley folds and
the edges as mountain folds. The folded pattern is similar to the diamond pattern with
the dierence that the diagonal valley folds are not in the same plane but describe a helix.
A single row of the pattern is identical to a herringbone pattern where one base of the
trapezoid is reduced to a point.
This pattern can only be folded with the second method by drawing the pattern on
the paper before folding it.

The shape of the folded pattern is dicult to control.

We

decided to keep this pattern because we were puzzled by its close relationship to the two
other patterns.

mountain folds
valley folds
Figure 3.3.1. Diagonal pattern

Diagonal patterns can be observed in thin cylinders which are compressed with a
rotation and in some plant structures [

HA05, Kre08, Kre02].

3.3. DIAGONAL PATTERN

Figure 3.3.2. Diagonal patterns

47

48

3. EXPERIMENTATION WITH PAPER CRAFT FOLDING

3.4. Discussion
We chose three patterns for further investigation for the following reasons:

The three patterns are composed of a series of parallel lines:

Diamond pattern: the diagonals of the diamonds are parallels.


Herringbone pattern: the bases of the trapezoids are parallels.
Diagonal pattern: the bases of the parallelograms are parallels.
This enables the unfolded patterns to be decomposed in long strips with parallel
edges, which is particularly interesting for folded plate structures with timberderived products. Indeed the size of most panels is an elongated rectangle (see
gure 2.3.4). One can suppose that folded plate structures based on these patterns
can be milled with a minimum of waste.

Not only timber panels, but a great

many construction materials are produced in elongated size: thermal insulating


material, water and wind proong sheets, exterior and interior cladding, etc. We
suppose that these patterns can be built reasonably priced.

The fact that the three dimensional shape of Diamond and Herringbone pattern
can be controlled by the folding method was decisive for their selection.

They

consist of a simply corrugated surface which is then deformed by reverse folds. In


paper folding this deformation happens in a two dimensional state on a plane surface which simplies the design of the form. We supposed that this property could
be assigned to the design in 3D modeling software. The amplitude of the simply
corrugated surface indicates the nal amplitude of the folded plate structure and
allows integration of structural considerations into the design process.

Finally, we were also attracted by the fact that these patterns exist in dierent
natural phenomenas like buckling [

HA05]

DF02]

or unfolding of leaves [

supposed that they have an inherent structural quality.

and

Part 2

Geometry of folded plate structures

CHAPTER 4

Simply-corrugated surfaces
4.1. Introduction
Take a paper, fold a rst crease that divides the paper in two parts, continue to halve
each part, deploy the creases and discover the folding. Start again, vary the size of each
crease, fold them oblique, deploy and discover a new form. Play with it ! (see gure 4.1.1).
Even though it seems very basic to design a simply-corrugated surface, the parameters
that dene such a surface are limited, the possibilities of varying the design are rich and
strongly characterize the nal design of folded plate geometries. This chapter will discuss
the following points:

First

We situate the geometric representation we use to represent and design the


folded plate structure and we dene a simply-corrugated surface.

Secondly
Thirdly

We describe poly-surfaces corrugated by parallel folds.


We describe poly-surfaces corrugated by oblique folds.

Figure 4.1.1. Simply-corrugated surface


51

52

4. SIMPLY-CORRUGATED SURFACES

4.1.1. Orthogonal projection of folded plate structures.

To describe and repre-

sent the Origami based folded plate structures we use the system of orthogonal projection.
The folded plate structure is placed in a system of orthogonal coordinates

x, y, z

and pro-

jected to three projection planes. The third angle projection is used and the three main
projection planes are as follows (see gure 4.1.2):

Horizontal plane xy (top view )

it shows the width and the depth of the projected object.

We annotate the projection of an object in the horizontal plane

0
sux . For example the projection of a point
0
annotated a .

Frontal plane xz (front view )

xy

with the

on the horizontal plane

xy

is

it shows the width and the height of the projected object.

xz with the sux


plane xz is annotated

We annotate the projection of an object in the frontal plane

00 . For example the projection of a point


a00 .

Prole Plane yz (right side view )

a on

the frontal

it shows the depth and the height of the projected ob-

ject. We annotate the projection of an object in the prole plane

000 . For example the projection of a point


sux
000
annotated a .

yz

on the prole plane

Orthogonal projection is a parallel projection and has the following proprieties [

with the

yz

is

PAHK07]:

The projection of a line is a line. In the special case when a line is parallel to the
projection rays the projection of the line is a point.

The projection of parallel lines non-perpendicular to the projection planes are


parallel lines:

ABkCD A0 B 0 kC 0 D0 .

The ratio of length of two segments of a line is preserved in the projection:

A0 B 0
B0C 0

AB
BC

Parallel line segments of equal length in space are projected to parallel line segments with equal length in the projection plane.

Figure 4.1.2. Orthogonal, third angle projection

53

Height

Height

4.1. INTRODUCTION

54

4. SIMPLY-CORRUGATED SURFACES

4.1.2. Simple corrugations.

The most basic way to fold a paper is to create a

succession of parallel mountain and valley folds. The orientation of a fold denes whether
a fold is a mountain fold or a valley fold.
We denote mountain folds as convex and valley fold as concave folds. In a 3-dimensional
space with given coordinates

x, y

and

this corresponds to trigonometric orientation.

Reading from left to right, convex folds are marked with (-), since the rotation from one
face to another is a negative rotation (clockwise rotation). Concave folds are marked with
(+) since the rotation from one face to an other is positive (counter-clockwise rotation)
(see gure 4.1.3).
Take a rectangular strip of paper with creases parallel to one edge. For any kind of
such a gure there exist two boundary states of the paper (see gure 4.1.4):

Developed or completely unfolded


in a horizontal plane

xz

view

Completely folded

the paper is at. The folds are a series of parallel lines

xy .

The paper takes its maximum extension. The frontal

and the right side

yz

view show a single horizontal line.

the paper takes its minimum extension. Now all the creases are parallel

lines in a vertical plane

xz

. The top view

represent a line. In the front view

xz

xy ,

as well as the right side

yz

view

we see a series of parallel, horizontal lines

within a rectangle.

Partially folded

In between these two states the paper can take many dierent shapes.

The right side view

yz

shows a polygonal line: the

folded surface. The top view

xy

corrugation prole

and the right side view

yz

of the

show parallel lines

and indicate the height and depth of the folded paper.


Instead of being parallel, the succeeding creases can be oblique to each other. In a simple
corrugation with oblique creases, the creases do not intersect within the folded surface but
outside the folded surface or at its edge. Similar to the parallel corrugation three typical
congurations can be observed:

Developed, partially folded

and

completely folded.

y
x
e n+1
en

en

e n+1

z
x

Figure 4.1.3. Notation of concave (+) and convex (-) fold

4.1. INTRODUCTION

a) Parallel folds

b) Oblique folds

unfolded

partially folded

completely folded

Figure 4.1.4. Parallel and oblique corrugations: dierent states of folding

55

56

4. SIMPLY-CORRUGATED SURFACES

4.1.2.1.

Analogy of folding and projection.

It is interesting to note the similarity be-

tween the folding process and the orthogonal projection. Let us suppose that the folding
and unfolding is linear, along a vector perpendicular to the frontal projection plane

xz .

The folding vector is then parallel to the projection rays. If we observe the transition from
unfolded to completely folded, we nd out that during the folding the faces contract along
the

axis and so does the horizontal projection

the frontal plane


jection

xy

xy

xy .

It is as if the faces were projected onto

but because their position is more and more inclined, the frontal pro-

expands along the

axis. If we compare the frontal projection

xy

of a partially

and a completely folded geometry, they are very similar: both projections could represent a partially, as well as a completely-folded geometry.

Normally a three-dimensional

object is projected onto a two-dimensional plane. If we invert this process and project the
two-dimensional drawing of the front view into the three-dimensional space, this is similar
to unfolding a paper with the dierence that in real unfolding, the dimension along the
vertical axis

diminishes, where as in the projection it doesn't vary. It is the corrugation

prole that indicates how far we project/unfold the faces of the frontal view into 3D space.
We can now substitute the unfolding by the projection which has the advantage that the
1

geometry doesn't vary in the frontal projection .

This becomes particularly important

when we bend straight creases by reverse folds, because the bending angles vary during
the unfolding of paper. It will allow us later to directly draw a folded geometry in space
by indicating its form in the frontal view and the deployment of the faces in the prole
view (corrugation prole). The three-dimensional geometry can be simplied and dened
by two, two-dimensional drawings. The system of projections we use to analyze the folds
becomes a tool to design them.

The unfolding by projection is a shear transformation of the faces.

4.1. INTRODUCTION

57

We dene simply-corrugated surfaces, as surfaces folded by a series of mountain and valley


folds, where the creases never touch or cross within the surface. Each face of the surface
is dened by two creases, the edges of the face. Each face is assumed to be planar.
A section across the folds shows the corrugation prole. The corrugation prole of parallel
sections is either constant or varies (see gure 4.1.5). If the corrugation prole is constant
throughout two parallel sections, the folds are parallel to each other (see gure 4.1.5 a)). If
the corrugation prole of parallel sections varies, the folds are oblique (see gure 4.1.5 b)).
Two adjoining crease edges intersect either outside of the folded surface or on its edge.
We will mainly consider corrugation proles with alternating convex (-) and concave (+)
folds but other combinations are possible.
A simply corrugated surface is characterized by its corrugation prole.

a)

b)

Figure 4.1.5. Simply-corrugated surfaces

58

4. SIMPLY-CORRUGATED SURFACES

4.2. Parallel folds


Simply-corrugated surfaces composed of parallel folds are characterized by a single
corrugation prole.

This prole is constant throughout the surface.

To dene a series

of parallel folds, a corrugation prole can be extruded along a vector that indicates the
width of the folded geometry. We use the following parameters to that characterize the
corrugation prole (see gure 4.2.1):

Corrugation mid-line CM it describes the general shape of the corrugation.


Amplitude A indicates the amplitude of each corrugation edge and the corresponding faces.
Total amplitude Amax indicates the amplitude of the whole corrugation.
Inclination angle indicates the inclination of the edges and the corresponding faces. It
is the angle between a horizontal axis and the corrugation edge. Its value is
absolute.

Interval I
Width W

indicates the horizontal distance between two corrugation edges.


measures the length of the corrugation edges respectively the width of the
faces.

Orientation (+/-)

- +

- - +

Curvature
(Concave + / Convex -)

idt h

(w )

Amplitude (A)

ew

Corrugation midline (CM)

edg

Total amplitude (Amax)

indicates whether the folds are concave (+) or convex.

Interval (I)
inclination angle ( )

Figure 4.2.1. Corrugation prole of parallel folds

4.2. PARALLEL FOLDS

4.2.1. Corrugation mid-line.

59

It describes the general shape of the corrugation and

is either straight, curved or a poly-line. The corrugation prole oscillates around the midline.

The way the corrugation oscillates around the mid-line inuences the inclination

angle of the edges.

In gure 4.2.2 a) and b) all edges have the same width

and are

symmetric about the corrugation mid-line. With a straight mid-line (see gure 4.2.2 a))
the inclination angle

is constant, whereas it varies when the mid-line is curved. Figure

4.2.2 c) and d) show corrugations which oscillate with constant inclination angle
the mid-line. They appear as less regular because the edge width

around

varies. The variations

get stronger the more the mid-line is inclined in reference to a horizontal line.
corrugation mid-line is not straight, it strongly inuences the total amplitude

Amax

If the
of the

corrugation.

W1

A1

I1

a)

5
3

W1

b)

A1

I6

I4

I5

I3

W5
c)

A max

I2

I1

W3

W1
A max

W4

W2

A1
I6

I5

I4

I3

I2

I1

d)
W4

W3
A max

W1
1
1

W2

I4

I3

I2

A1

I1

Figure 4.2.2. Corrugation mid-line

y
x

CM

60

4. SIMPLY-CORRUGATED SURFACES

4.2.2. Orientation of the folds.

The order of convex and concave folds strongly in-

uences the architectural expression of folded plate structures. If the most common order
is an alternation of convex and concave folds, some other orders are possible. The inclination angle of such proles cannot be constant. Figure 4.2.3 a) and b) show corrugation
proles with horizontal edges that imply a succession two folds with the same orientation.
This type of corrugation separates edges that have mainly structural functions, from edges
that mainly cover the space. The expression of the prole becomes more box-shaped (see
gure 4.2.3 b)). When two or more concave respectively convex folds succeed each other,
the inclination angles get very small and the corrugation prole loosens its sharpness and
becomes more curvilinear (see gure 4.2.3 c) and d)). If such rounded proles might be
interesting for architectonic expression they are probably less ecient in their structural
behavior.

W1

A1

W2

I1

a)

W1

A1

W2

I1

b)

W2
-

d)

W2
-

+
+

A1

I1

W1

W2

2
1

W2

c)

W1

W2

W1 W1

A1

z
I1

Figure 4.2.3. Orientation of folds (convex and concave)

y
x

4.2. PARALLEL FOLDS

4.2.3. Amplitude.

61

Amplitude is an important parameter of the corrugation: it di-

rectly inuences the strength of the folded plate structure. Here we distinguish the amplitude

of each crease, which can be modied individually and thus reinforce the structure

locally, and the total amplitude of the corrugation

Amax

that is important because it in-

uences the possibility of bending the corrugation (see section 6.3 and gure 4.2.4 c) and
d)).

When we change the amplitude but do not vary the interval, the strength of the

structure gets doubly inuenced. The structural depth diminishes, but also the inclination
angle of the corrugation edges diminishes, and therefore the faces have less bearing capacity (see 4.2.4 a) and b)). If we can use amplitude to locally reinforce a corrugation, for
example the border that is particularly weak because it is not supported by other folds,
variation of amplitude can also be used for architectural reasons. Alternating small and
big folds, accentuating parts of the corrugation, can introduce rhythm to the enveloped
space, underline exceptional parts, and modify the intensity of light and shadow.

W1

A1

I1

a)

W1
1

A1
1

I1

b)

1
3

W1

W2

W3
A max A 2

A3 A4

A1

A max

I1

c)

W1

W2
A2

d)

I1

Figure 4.2.4. Amplitude of the corrugation prole

y
x

62

4. SIMPLY-CORRUGATED SURFACES

4.2.4. Inclination angle and interval.

The inclination angle

between a corrugation edge and a horizontal axis


inclination angle

With constant amplitude

closely related. When the interval

A,

x.

indicates the angle

We use an absolute value for the

inclination angle

and interval

are

between two creases is increased the inclination angle

diminishes. Thereby it would be interesting to nd the optimal inclination angle

for

a given amplitude. Each face should cover the largest interval possible and at the same
time guarantee good structural behavior. As the amplitude

A,

the inclination angle

be used to reinforce parts of the structure: the bigger the inclination angle

can

the better

the structural behavior under vertical load (see gure 4.2.5 d)) . As structures are also
charged by horizontal loads, the inclination angle

, in particular the the angle of the faces

at the edge of the structure, needs to be optimized for both solicitations. Dierences in
inclination can also be used to give an orientation to space and to direct light reection
(see gure 4.2.5 c)) .

4.2.5. Width of corrugation edges.


rameters of the corrugation.

The edge width

depends on the other pa-

For construction with cross laminated timber panels it is

limited to the maximal width of the panel type that varies for dierent manufacturers (see
gure 2.3.4).

W1

A1

I1

a)

W1

A1
1

I1

b)

W2

A1
W1

W2

d)

I1

I2

c)

A1

W1

I2

W1
I1

I1

Figure 4.2.5. Interval

y
x

and inclination angle

4.3. OBLIQUE FOLDS

63

4.3. Oblique folds


We dene oblique folds as developable surfaces composed of triangular faces or planar
quadrangular faces with non-parallel fold edges. The folds do not intersect within the surface. Two parallel cross sections show corrugation proles with parallel edges but dierent
width

. The parameters of the corrugation proles are the same as for parallel folds. We

propose two ways to design a poly-surface with oblique folds.

4.3.1. Design by two corrugation proles.

In this method we draw a rst cor-

rugation prole which denes the inclination of all corrugation edges.

We then draw a

second corrugation prole whose correspondent edges stay parallel to the rst prole, but
have dierent edge widths and intervals. By dening a distance between the two proles
and linking the corresponding vertices we can draw the poly-surface with oblique folds
(see gure 4.3.1).

With this method the control of the general shape is not very direct

and it may be arbitrary.

It may be useful for poly-surfaces with concentric fold edges

(see gure 4.3.1 b)).

The corrugation prole of non-parallel folds doesn't necessarily represent the dihedral angles between the
faces. The dihedral angle of two faces is situated in a plane normal to the crease edge. In oblique folds
the cross section representing the corrugation prole is not perpendicular to all fold edges.

a)

b)

y
x

f1

f2

f3

f10

e1 e2 e3

f1

f2

e10

f3

f10

e1 e2 e3

e10

y
Figure

4.3.1. Design

of

oblique

a) oblique folds b) concentric folds

folds

with

two

corrugation

proles

64

4. SIMPLY-CORRUGATED SURFACES

4.3.2. Design with a ruled surface.

Another way to design poly-surfaces with

oblique folds is by starting with a ruled surface.

We dene two corrugation mid-lines

placed in a chosen distance and sweep a straight line along the two curves. By dividing
the curves in an equal number of segments we can dene a series of strips on the surface
by linking the segments with the rulings (see gure 4.3.2 a)). Starting from this surface
we can proceed in two ways:
(1) We directly design a poly-surface by linking two opposite vertices of each strip by
a diagonal. The resulting poly-surface is very close to the ruled surface but has
the following disadvantages (see gure 4.3.2 b)) :

The inclination angle

of the faces is very small.

It depends on the dierence

of inclination of the corrugation mid-lines. Particularly in the zones where


the mid-lines are almost parallel, the faces are few inclined.

The order of alternating concave and convex folds is disturbed. In the zone
where the corrugation mid-lines have parallel tangents, and the inclination
angles are very at, two convex folds follow each other. This problem could
be answered by choosing the opposite diagonals starting from the point where
the mid-lines are parallel.

At the edge of the poly-surface the corrugation amplitude diminishes to zero.

(2) We link the vertices of the rulings by an a zig-zag line (see gure 4.3.2 c)). These
diagonals will be the convex folds of our folded poly-surface.

We then oset

the corrugation mid-lines. The oset distance corresponds to the amplitude we


want to give to the corrugation.

All vertices of the rulings that are not linked

by the convex fold line are projected to the oset mid-line.

This gives us two

corrugation lines. We can design the poly-surface by linking the convex folds and
the corrugation lines with triangular faces (see gure 4.3.2 d)). If we imagine the
ruled surface to be elastic and span on a rigid grid formed by the zig-zag line
of convex folds, we simply push down the surface at their edges in between the
vertices of the zig-zag line to create the valley folds (see gure 4.3.2 c) and d)).
This method to design oblique folded poly-surfaces is very advantageous:

The general form can easily be pregured.


It can be applied with all types of ruled surfaces.

If we want to design a

cylinder surface we simply choose two congruent mid-lines.

The reference surface can be chosen outside or inside. It depends whether


we dene the zig-zag line on the ruled surface as convex or concave folds.

The amplitude of the folds can be varied.


In the developed surface every second fold is almost parallel, which is advantageous for construction with long timber panels.

4.3. OBLIQUE FOLDS

a)

b)

z
y
x

c)

d)

e)

y
x developed
Figure 4.3.2. Design of oblique folds with a ruled surface

65

66

4. SIMPLY-CORRUGATED SURFACES

The method of drawing a poly-surface with oblique folds starting from a ruled surface
can be used when the corrugation mid-lines are oblique to each other in all points, for
example with a hyperbolic paraboloid which is generated with two straight lines oblique to
each other (see gure 4.3.3). The inclination angle

of the corrugation prole edges then

corresponds to the inclination of the two corrugation mid-lines. To increase the amplitude
at the edge of the poly-surface we simply elongate the rulings (see gure 4.3.3b)).

a)

b)

z
y

z
y
Figure 4.3.3. Design of oblique folds approaching a hyperbolic paraboloid

4.4. DISCUSSION

67

4.4. Discussion
Simply-corrugated surfaces are developable surfaces, composed of plane faces that form
a succession of convex and concave folds which do not intersect within the surface. They
are dened by their corrugation prole which is constant for parallel folds and varies for
oblique folds.
The mid-line and the order of convex and concave folds are the parameters of the
corrugation line that strongly shape the general and the local form of the corrugated
surface.
We propose to describe the general form as a ruled-surface where a straight line sweeps
along the corrugation mid-line. When the rulings are parallel they form a cylinder surface
which is single-curved. Cylinder surfaces can be used to shape parallel and oblique corrugated poly-surfaces. When the rulings change direction the ruled surface is doubly curved,
3

which only allows shaping of corrugated poly-surfaces with oblique folds .


The order of convex and concave folds, structures the folded surfaces and gives the
overall shape a basic character, which is then modulated by the amplitude, the inclination,
and the interval of the folds. These parameters decide the rhythm of the structure, the
way light and sound are reected, as well as the succession of light and shadow.

They

strongly dene the architectural character of the folded plate structure.


Simultaneously, amplitude and inclination angle will determine the structural behavior
of the geometry. These two parameters will also be of rst importance for the way simplycorrugated surfaces can be bent, inuence the foldability of the geometries, and the way
they can be oset.
The way a poly-surface is corrugated is crucial for the architectural character as well
as the structural behavior of a folded plate structure.

By intelligent modulation of the

corrugation prole parameters, we can design the most important aspects of a folded plate
structure.

It would be interesting to examine the design of folded plate geometries composed of multiple patches of
ruled surfaces.

CHAPTER 5

Reverse fold
5.1. Introduction

Figure 5.1.1. Reverse folds bend a straight fold

The geometries we are interested in are all based on the reverse fold (see gure 5.1.1).
By using the reverse fold, straight folds can change their direction in space. Therefore the
reverse fold is our main tool which allows us to design the shape of folded plate structures.
This chapter is divided in three sections which describe the following points:

First

We describe the reverse fold in 2D space as it is mainly used in origami. This


allows easy understanding of the nature of the reverse fold as a reection about
a line.

Secondly

We look at the reverse fold in 3D space where it can be described as a reection


about a plane.

Thirdly

We investigate the reverse fold in orthogonal projection. The properties of orthogonal projection allow us to simplify the design of three dimensional reverse
folds and reduce them to two dimensions.

The bending of the straight folds

can be determined by a simple line in the frontal plane

prole.

xz :

the

cross section

Thus, the geometry of folded plate structures can be dened by two

lines, the corrugation prole and the cross section prole.


In a series of investigations we examine how dierent parameters inuence
the shape of reverse folds and establish the limits of the parameter variations.
69

70

5. REVERSE FOLD

We rst investigate parallel reverse folds in function of their position in


space and the inclination angle of their corrugation prole edges.

These pa-

rameters inuence shape and foldability of reverse folds.


Secondly we investigate the bending of non-parallel creases by reverse fold.

5.2. Reverse fold in 2-dimensional space - reection on a line


The reverse fold is one of the base techniques of Origami [
the direction of a straight crease.

Eng89].

It is used to change

Generally the reverse fold is folded at so that the

resulting gure is two dimensional.


A two dimensional reverse fold can be dened as follows:

A straight

main crease m is bent by two side creases s which divide the initial faces oblique

to the main crease. Two faces of the crease stay in position, whereas the other two are
reversed about the side creases: They are reected about a line dened by the geometry
of the side folds (see gure 5.2).

m and the side folds s is the side fold


m is the bending angle : = 2 .

The angle between the main crease edge


The angle between the main fold edges

angle .

The folding process of a two-dimensional reverse fold clearly explains its nature and
geometry. Figure 5.2.1 shows the folding process step by step:
a)
b)

c)

d)

e)
f)

g)

h)

F1 and F2 by a main crease m.


Face F2 is folded along the line m so that face F2 and F1 superpose. The folding
corresponds to a rotation of F2 around the axis m. The rotation angle is . The
faces F1 and F2 form the straight main-crease m.
Half of the folded strip is rotated around a second crease s , which is oblique to
the main-crease m. The faces F1 and F2 lay under the faces F4 and F3 . This
imposes a bending of the main crease m.
The folded strip is deployed so that all faces are in a horizontal plane xy . The
initial face is now composed by two pairs of faces F1 , F2 and F3 , F4 , which are

is concave whereas
symmetric about the main crease m . The main crease m
+

one side crease is convex s1 and the other concave s2 .


The main crease m is folded to an intermediate position.
From this position F3 is rotated counterclockwise around s1 and F4 is rotated
clockwise around s2 . The inside of the faces F3 and F4 is turned outside and the
+

main-crease changes from concave m to convex m .


The reverse fold is completely closed. The faces F3 and F4 are reversed around
+
the side crease s . The faces F1 and F2 lie in between the faces F3 and F4 .
and a
The deployed reverse fold shows the main fold composed of a concave m
+ segment. The two side folds, s+ and s+ , are convex. Otherwise the
convex m
1
2
A rectangular face is divided in two equal parts

geometry of the faces remains unchanged.

5.2. REVERSE FOLD IN 2-DIMENSIONAL SPACE - REFLECTION ON A LINE

a)

71

e)

F3
m

s
m

F1

F1

F2

F2

b)

f)
s

F2

F3
F4

c)

F1 F2

g)

F4
m

d)
F3

F4
ms +1

z
y
x

F3

F1

h)

s 2-

F3
m-

F2

F4
m+
s1+

F1

Figure 5.2.1. Folding a two dimensional reverse fold

F1

s 2++
mF1

F2

72

5. REVERSE FOLD

The reversing of the faces

F3

F4

and

corresponds to a reection about a line

faces (see Figure 5.2.2a ). The position of the reection line


the side fold
and

a2

s.

The segment

the reection line

r.

b2 a2

determines the side fold

The edge vertices

a3

and

b3

of the

is given by the geometry of

and a line passing through

of the face

F3

b2

are reected about

r.
b1 b3 and the side fold edge b2 a2
m
. Its opposite angle b3 b2 b3 and the reection of the opposite angle

We dene the angle


as the

side fold angle

r
b2 bm
3 b3 are identical to

a2 b2 b1

between the main fold edge

The angle between the edges

= 2.

b1 bb

and

b2 br3

of the main crease is the

bending angle :

The size of the bending angle is inversely proportional to the bending of the

main crease.
This shows the strong relationship between the bending angle

The more acute the side fold angle

the weaker the bending of the main crease. The

maximal bending is achieved with a bending angle


angle

and the side-fold angle

= 0,

which corresponds to a side-fold

2 . The side fold is perpendicular to the main fold and all the faces superpose.

The developed reverse fold shows the angular symmetry of the side folds which is
characteristic for two dimensional reverse folds (see Figure 5.2.2b ).

r
a3

a2

b3

b2
m

a1

b1
= -2

b3

b3
r

a3

a) folded

a2

a3

b2

b3

a1

b1

b) deployed
Figure 5.2.2. Two-dimensional reverse fold

5.3. REVERSE FOLD IN 3-DIMENSIONAL SPACE - REFLECTION ABOUT A PLANE

73

5.3. Reverse fold in 3-dimensional space - reection about a plane


The reverse fold in 3-dimensional space has similar characteristics as the reverse fold in
2-dimensional space (see gure 5.3.1). The main dierence is that it can take intermediate
positions between the at, undeployed fold and the completely closed fold. The bending
angle

of the main crease changes with the variation of the inclination angle

of the

faces.

The reverse fold in 3-dimensional space is a reection about a plane. The bending of the
main crease creates a vertex and two side folds which divide the initial faces. The second
part of the faces are reected about a

reection plane R,

dened by the vertex and the

two side folds.


The reection plane

Kli97].

is perpendicular to the interior angle bisector of the main crease

edges [

The size of the bending angle


the inclination angle

of the main crease is function of the side fold angles

of the faces.

The maximal variation of the bending angle

in function of the inclination angle

the faces is in direct relationship with the size of the side-fold angle
side-fold angle

and

the smaller the maximal variation of the bending angle

of

The smaller the

The reverse fold can be considered as a particular case of a developable 4-degree vertex
as dened by Human [

Huf76].

He discussed this type of vertex in regard to Gaussian

curvature which implies spherical geometry. We propose to present some of the properties
of the reverse fold in solid geometry.

Figure 5.3.1. Reverse folds

74

5. REVERSE FOLD

F1 and F2 with a common edge b1 b3 that


x axis (see gure 5.3.2a)). To simplify our
symmetric to a vertical plane xz passing through

Consider two congruent rectangular faces

form a straight, convex crease m , parallel to the


considerations the two faces are placed
the crease edge

b1 b3

The opening of the main crease

F1

and

is dened by the

dihedral angle

of the two faces

F2

At the inection point


original faces

F1

and

F2

b4

are split into four faces

b4 . Two convex side folds s+


1 and
a2 and c2

m bends
F1 , F2 , F3 , F4

the convex main fold

and gets concave

m+ .

The

arranged around the vertex

s+
2 run from the inection point

b4

to the edge points

The angles between the side creases

a2 b4 br2 and

2 =

s
1

and

s
1,

and the main crease

m+

are:

1 =

br2 b4 c2 .

Let us study the relationship between the obverse and the reverse part of the main

c2 we project a

+
perpendicular line to the axis of the convex and to the concave main-crease m , m . The
r
angle a2 b2 c2 and a2 b2 c2 measure the dihedral angle of the main-crease and its inversion.
r
r
Because of the equal length of the segments a2 b2 = a2 b2 , b2 c2 = b2 c2 and the common edge
a2 c2 , the triangles a2 b2 c2 and a2 br2 c2 are congruent. Therefore, the dihedral angle of the
+
1:
convex main crease m is equal to the dihedral angle of the concave main-crease m
crease (see gure 5.3.2b)). From the end points of the side-folds

a2

and

a1 b1 c1 = a2 br2 c2

(5.3.1)
The triangles

a2 b4 b2

and

a2 b4 br2

b4 b2 d and b4 br2 d
b4 b2 = b4 br2 and b2 d = dbr2 and

are congruent by denition. The triangles

are congruent because of the equal length of the segments


the right angle these segments include.
The congruence of the three triangles

b4 br2 d

implies that the faces

segments

b4 a2

and

F3

and

F4

a2 b2 c2 = a2 br2 c2

are a reected

a2 b4 b2 = a2 b4 br2 and b4 b2 d =
about a plane R dened by the
,

b4 c2 .

b4 d of the reection plane R and the plane dened by the segments


r
b4 b3 and b4 b3 of the main-fold is the exterior bisector of the angle b1 b4 br3 . The normal to
r
the plane R in b4 is the interior bisector of the angle b1 b4 b3 [
].
The intersection

Kli97

We consider the absolute value of the angle

5.3. REVERSE FOLD IN 3-DIMENSIONAL SPACE - REFLECTION ABOUT A PLANE

75

b1
mb3
2
1

F2

c1
F1

a1

a)

c3

a3
b1

m-

b4

F2

F1

b2
b3
s

2
1

F3

F4

c1
s 1-

a1

a2

d
c2
1

c3
a3

r
2

m+

z
r

b)

F3

y
x

F4

a3r
b3r
b4

a2

'
1

b'2

c)
d
Figure 5.3.2. Reverse fold

c r3

76

5. REVERSE FOLD

The bending angle

indicates the magnitude of the bending of the reverse fold.

depends on the dihedral angle of the main-crease

and the angle of the side creases

It

In order to be able to take into account asymmetric positions of the two faces, we
consider the inclination angle
main crease
and

F2

and

of each face instead of the dihedral angle of the

1 and 2 are the dihedral angles


xy : 1 = c1 a1 b1 and 2 = a1 c1 b1 .

Inclination angles

and a horizontal plane

inclination angles

between the faces

F1

The sum of the two

is supplementary to the dihedral angle of the main fold

such that:

(1 + 2 ) = a1 b1 c1
1 and 2 are equal and we can be described
as follows (see gure 5.3.2b) and c)):

In this particular case the inclination angles


the relationship between the angles

and

= 2

(5.3.2)

db2 r
)
b4 b2 r

(5.3.3)

= arctan(

(5.3.4)

db2 r = sin ab2 r

b4 b2 r =

(5.3.5)

a2 b2 r
tan

Substituting 5.3.5 and 5.3.4 in 5.3.3 and substituting 5.3.3 in 5.3.2 gives the relationship
of the three angles:

(5.3.6)

= 2arctan(

sin a2 b2 r tan
) = 2arctan(sin tan)
a2 b2 r

The reverse fold has two limit positions: completely opened or completely closed. These
two positions correspond to the inclination angles

min = 0 and max =

bending angles are:


(5.3.7)

min = 2arctan(0 tan) =

and
(5.3.8)

max = 2arctan(1 tan) = 2

2 . The associated

5.4. REFLECTION - DISAMBIGUATION

77

5.4. Reection - disambiguation


Geometries created by folding plane surfaces are often generated by reections. The
term reection can be understood in two dierent manners: as mathematical reection
and as physical reection. For disambiguation we shortly explain each denition.

Reection as a

mathematical term [PAHK07]:

into its mirror image (see gure 5.4.1 a)).

The reection transforms an object

The object is situated in the mirror, on the

other side of the mirror surface. We refer to mathematical reection as reection

about

line or a plane. The reected object is a reversed copy of the original. Therefore, reection
is an opposite congruent transformation. In 2-dimensional space, we reect objects
line and in 3-dimensional space

about

a line or

about

about

a plane. The object and its reection


2

have equal distance to the reection line or plane respectively .


Reection as a

physical term

surface (see gure 5.4.1 b)).

o
For example a light ray changes in direction by reection o
: A physical object in motion or a wave bounces

a
a

surface. In contrary to the mathematical reection, the object doesn't cross the reection
surface. We refer to physical reection as reection

o

a surface. When light reects

a plane surface the incident angle of the light ray is equal to the reection angle.

o

The

incidence angle and the reection angle are measured with reference to the normal to the
surface.
The

folding proces s can be described as reections about

a plane. In the reverse fold a

straight crease is split by a surface and one half of the split surface is reected about the
splitting plane (see gure 5.4.2).
The

folded surface can be described as a reection o

a plane. In a reverse fold, similar

to light rays, the straight edges of the main creases reect

o

a surface dened by the side

folds (see gure 5.4.3). In folding, this principle is only valid for straight creases that are
bent by a reverse fold.

(Reection about a line in 3D space is not an opposite congruent transformation and can also be obtained
by rotation of the object around the reection axis by the angle ).

a1
a2
a

m
1

a 2m
a 2r

a)

r1

a 1r
Figure 5.4.1. a) Reection

ar

ai

r1

b)

about

a plane b) Reection

o

a plane

78

5. REVERSE FOLD

As gure 5.4.2 and gure 5.4.3 show, the two kinds of reections are closely related in
folding geometries. To distinguish them we will always use the term reection
referring to mathematical reection and reection

about, when

o, when referring to physical reection.

b1 '' c1r ''


a1r ''

b1
b1m '' a1m '' c1m ''

R''

c1r

R
a1r

a''1 c''1

b''1

a1

Figure 5.4.2. Folding the reverse fold: reection

a i '' c i ''

n''a

n b''

b''r
b i ''

''

i
b

r
b

''

a
i
a

''

r
a

''

ar ''c r''

about

a plane

nc
b

b1

ci

nb

na

R''
ar
z

z
x

y
x

Figure 5.4.3. The reverse fold as reection

o

c1m
c1

a1m

b1

a plane

cr

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

79

5.5. Reverse fold in orthogonal projection


In this section we investigate reverse folds in orthogonal projection. We place a single
crease in 3-dimensional space and consider its projections on the three main projection
planes: horizontal plane

xy ,

frontal plane

xz

and prole plane

yz .

The main crease is positioned either parallel or oblique to the frontal plane
The reection plane

is perpendicular to the frontal plane

xz .

xz.

This conguration enables generatation of the folded plate geometry by two poly-lines: the
corrugation prole and the cross section prole.

First

We show the advantage of positioning the reection plane


the frontal plane

Secondly

perpendicular to

xz .

We investigate reverse folds with the main crease parallel to the frontal plane

xz .

We vary the parameters dening the corrugation prole, show their inuence
on the geometry of the reverse fold and the limits of the parameter variations.

Thirdly

We investigate reverse folds oblique to the projection plane and show the consequences of the oblique position to the geometry of the reverse fold.

Fourthly
Fifthly

We dene the limits of the bending angle of reverse folds.


We dene the amplitude variation in the bending zone.

5.5.1. Reection plane perpendicular to the frontal plane.


nR to the reection plane
+

of the main fold crease edges m and m .


It has been shown that the normal

When the reection plane

R is the interior angle bisector

R is perpendicular to the frontal plane xz the following properties


xz (see gure 5.5.1):

are conserved in the frontal plane

The projection of the normal


plane

R.

The projection of the normal

+
the main fold edges m and

nR is perpendicular to the projection of the reection


nR is
m .

the interior angle bisector of the projection of

As a consequence the projection of the reection plane

is the exterior angle

bisector of the projection of the main fold edges.


These properties are a key concept of the proposed method. They will allow denition of
the bending of simply-corrugated surfaces in the frontal plane with a poly-line: the cross
section prole.

a that reects o a reection plane R perpendicular to the frontal plane


xz . The line a represents the edge of a main fold crease. The reected line a is composed
i
r
of two edges: the incident edge a , and the reected edge a , which are equal in length.
The normal to the reection plane R is nR . It is the interior bisector of the angle formed
i
r
by the edges a and a .
Consider a line

80

5. REVERSE FOLD

The normal
plane

nR

and the projection lines form a plane perpendicular to the reection

and perpendicular to the frontal plane

xz

: The projection of the reection plane

nR are perpendicular.
r
i
The line a1 a1 r is parallel to the reection plane R . The normal nR is perpendicular
i r
i r
to a1 a1 r and divides the line in two equal segments. The projection of a1 a1 r is parallel
and the projection of the normal

the reection plane

i
edges a and

. The projection of the normal nR divides the


4
r
i
projection of a1 a1 r into equal segments : The projection of the normal nR is the interior
i
r
bisector of the angle formed by the projection of the edges a and a and the projection of
to the projection of the reection plane

is the exterior bisector of the angle formed by the projection of the

ar .

The projection of parallel lines non-perpendicular to the projection plans are parallel lines.
The ratio of length of two segments of a line is preserved in the projection.

reflection plane R

R''

ar
a r ''
a i ''

nR''

ai
a

nR

r
1

z
y

a 1i
x frontal pla

a 1i

ne xz

Figure 5.5.1. Reection of a line about a plane perpendicular to the pro-

jection plane in orthogonal projection

a 1r

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

5.5.2. Reverse fold parallel to the frontal plane.

81

In a rst set of investigations

xz

a single crease is positioned with the axis of the main fold parallel to the frontal plane

xy .

and parallel to the horizontal plane


plane

R.

xz

A reection plane

R,

perpendicular to the frontal

, splits the crease in two parts. The second part of the crease is reected about

The position of the reection plane

is identical for all cases.

Starting with a crease with congruent faces and congruent inclination angles

of the

faces, we then vary chosen parameters of the initial crease in order to show the consequences
for the geometry and the foldability of the reverse fold.
We examine four dierent congurations:

Case 1

The faces and the inclination of the faces are congruent (F1

= F2 , 1 =

2 , W1 = W2 , I1 = I2 , A1 = A2 ).

Case 2

The width of the faces is dierent; the inclination angle

F2 , 1 = 2 , W1 6= W2 , I1 6= I2 , A1 6= A2 ).
The faces and the inclination angle are unequal,
(F1 6= F2 , 1 6= 2 , W1 6= W2 , I1 6= I2 , A1 = A2 )

Case 3
Case 4

is congruent (F1

6=

amplitude stays constant

The edges of the faces are not parallel to the crease edge, the inclination angle

is congruent. (F1

= F2 , 1 = 2 , W1 6= W2 , I1 6= I2 , A1 6= A2 , W, I

andA

vary).
5.5.2.1.

Case 1: reverse fold with congruent faces and congruent inclination angles .

Case 1 (F1 = F2 , 1 = 2 , W1 = W2 , I1 = I2 , A1 = A2 )
This basic conguration of the reverse fold corresponds to reverse folds made in paper
folding. Due to its symmetry about a vertical plane, formed by the main crease edges
it is completely foldable: The inclination angles
the side fold angle

m,

of the faces are congruent and therefore

are congruent too.

xz is very similar to a two dimensional reverse fold


of the reverse fold can be represented by a cross
section prole parallel to the main crease edge m. We have seen that with reection
planes perpendicular to the projection plane, the projection of the reection plane R is the
The projection in the frontal plane

(see gure 5.2.2). The bending angle

exterior angle bisector of the projected main fold edges. This allows us to draw a cross
section prole in the frontal plane

xz

which denes the bending of a simply-corrugated

surface. The corrugated surface can then be reected about planes dened by the exterior
angle bisectors of the cross section prole.
The

cross section prole

plane

yz

in the frontal plane

xz

and the

corrugation prole

in the prole

are sucient to dene the geometry of the reverse fold. The cross section prole

denes the bending angle

of the reverse fold and the medial length of the facets. The

cross section prole is the mid-line of the reverse fold edges which are parallel to it. In
the frontal plane

xz ,

the edges of the reverse fold reect o the exterior angle bisector

R00

dened by the cross section prole. The distance from the cross section prole to the face
edges is given by the corrugation prole and corresponds to half the amplitude
fold.

of the

82

5. REVERSE FOLD

Consider a straight crease composed of two planar faces

F1

and

F2

(see gure 5.5.2).

The crease is parallel to the x axis and the rectangular faces are congruent and symmetric

R is dened such as it is perpendicular to the frontal


plane xz . The reection plane R splits the two initial faces (F1 , F2 ) along the plane a2 b2 c2
into four faces F1 , F2 , F3 , F4 . Face F3 and F4 are reected about the plane R to create the
to crease edge

b1 b3 .

A reection plane

reverse fold.
In the frontal plane

xz ,

the projections of the crease edges

b001 b002 b003 , a001 a002 a003

and

c001 c002 c003

R00 which is the projection of the


reection plane R . Due to the perpendicular position of R to the frontal plane xz , the
00
symmetry properties are conserved in the projection. The face F3 is symmetric to the face
F3r 0 '. Their common edge a002 b002 is a segment of R00 , the symmetry axis about which the
faces reect each other. In the frontal projection xz , the bent edges appear as reections
00
o a line R . All edges are parallel and have the same bending angle . Therefore we
can dene a single cross section prole d1 d2 d3 parallel to the edges a1 a2 a3 , b1 b2 b3 and
c1 c2 c3 . It is positioned as a median prole between the outer edges of the reverse fold.
stay parallel (see section 4.1.1) They reect about a line

The distance from the cross section prole and an edge of the reverse fold corresponds to
half the amplitude of the reverse fold. The frontal projection of the reection plane
the exterior angle bisector of the cross section prole

yz

The prole plane

a000
1,

b000
1,

R00

is

d1 d2 d3 .

shows the corrugation prole of the reverse fold:

c000
1 indicate the inclination angle of the faces

and

2 .

the points

The amplitude

of

the reverse fold corresponds to the vertical distance between the edges of the faces.
Each projection gives some specic information about the reverse fold:

Horizontal plane xy:

The interval

In

of the fold edges appears clearly as a succession of

parallel lines

Frontal plane xz :

The cross section prole is the main information of the frontal view. It

indicates the bending angle


The amplitude

Prole plane zy:

of the reverse fold and the length of the face edges.

of the crease also appears clearly.

The corrugation prole characterizes the inclination angle

their interval

Developed surface xy:


angles

and

and their amplitude

A.

The faces are symmetric about the crease edge

of the faces,

m.

are congruent. The fold can be completely closed.

The side fold

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

c r3'

c 2'

c 3'

F4'

b 3'

r
3

c3

c 1'

a3

F'2

F'4

b3

I2
b'

b 2'

r
3

a 2'

c1

F1

b1

F4 F4r

F3

y
x

a 1'

a'

F2

a1

b2

F'1

F3'

a 3'

F3

c2

F4

a2

b 1'

I1

F'3

83

a 3r

c 3r

r
3

y
x

R''
a 3''

a ''2

F''
3

F''
1 F''
2
d1

d2
b 2''

b 3''

a 1''' a '''
2

a 1''

b 1''

A/2
A/2

c 1''' c '''
2

A
1

b 1'''

2
r

r
F3 '' F4 ''
r
3

b ''

a 3r '''

z
y

c d2

c d3

F4
b d3

F4 '''

F3 '''

a 3r ''

d3

c 3r '''

b 3 '''

I1

I2

c d1

F2

b d2

b d1
1

F3
a d3

F1
a d2

a d1

y
x

developed

Figure 5.5.2. Reverse fold with congruent faces and congruent inclination angles

84

5. REVERSE FOLD

Within the following we illustrate how these two proles can be used to generate a
folded plate geometry step by step.

Simply-corrugated surface

(see gure 5.5.3).

a)

Design of the corrugation prole in the prole plane

b)

Determination of the maximal amplitude


frontal plane

xz .

Design of a generatrix

Amax

yz .

and its midpoint

parallel to the

am

in the

axis originating in

am .
c)

Generation of parallel creases using the generatrix


as directrix. In the frontal plane

xz

and the corrugation prole

the generatrix is the mid-line of the outer

edges of the folded plate geometry.

a)

z
x

z
x

c)

y
x

b)

am

Amax

y
x

z
y

y
x

Figure 5.5.3. Generation of a folded plate geometry 1

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

Cross section prole

(see gure 5.5.4).

a)

Design of a cross section prole.

b)

Translation of the generatrix

and the simply-corrugated surface to the point

of the cross section prole.

am of the generatrix g and the simply-corrugated surface


so that the generatrix g and the edge ab of the cross section prole superimpose.

c)

Rotation about point

c
d

b
a
am

a)

z
y
x

a
z

b)

z
y

b
a
z

c)

85

z
x

z
y

y
x

Figure 5.5.4. Generation of a folded plate geometry 2

86

5. REVERSE FOLD

First reverse fold


R1

a)

(see gure 5.5.5).

is dened by the exterior bisector of the angle

segments of the cross section line.

R1

abc

formed by the rst two

is perpendicular to the frontal plane

We split the simply-corrugated surface by the reection plane


b)

xz .

R1 .

Reection of the second part of the simply-corrugated surface about the plane

R.
c)

The folded plate geometry is now bent by an angle


angle

abc dened by the cross section line.

corresponding to the

The crease edges of the folded plate

geometry are parallel to the rst two segments of the cross section line.

R1

R1

a
z

a)

c
b

R1
R1

a
z

b)

c)

z
x

z
y

y
x

Figure 5.5.5. Generation of a folded plate geometry 3

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

Second reverse fold


a-c)

(see gure 5.5.6).

The steps a and b of gure 5.5.5 are repeated using a reection plane
by the exterior bisector of the angle

c)

87

The frontal projection

xz

bcd

R2 dened

of the nal folded plate geometry shows that all main

crease edges of the folded plate geometry are parallel to the according segments
of the cross section prole.

c
d
z

a)

R2

R2
z

z
y

c
b

d
z

b)

z
x

c)

R2

R2

z
y

y
x

Figure 5.5.6. Generation of a folded plate geometry 4

88

5. REVERSE FOLD

5.5.2.2.

Case 2: reverse fold with non-congruent faces and congruent inclination angles.

Case 2 (F1 6= F2 , 1 = 2 , W1 6= W2 , I1 6= I2 , A1 6= A2 )
The case we studied in section 5.5.2 is symmetric: in their original position the faces
and

F2

F1

are congruent and in a symmetric position about a vertical plane passing trough

the crease axis.

In the following we consider some variations of this gure.

section prole remains unchanged.

The cross

The rst parameter we change is the length of the

corrugation prole edges. The inclination angles

and

of the faces remain constant

(see gure 5.5.7).


With constant inclination angles
prole varies amplitude

the variation of the edge length of the corrugation

A and interval I

of the folded plate geometry. The side fold angles

stay constant: the reverse fold can be completely closed.

Figure 5.5.7 is very similar to gure 5.5.2 . The main dierences are the following:
As a consequence of the modication of the corrugation line the faces
have dierent amplitudes

and dierent intervals

I.

F1

and

F2

This can be observed in the three

projection planes:

Horizontal view xy the interval a01 b01 is smaller than the interval b01 c01
Frontal view xz the projected edges a001 a002 a003 and c001 c002 c003 do not superpose anymore.
are shifted and indicate the dierent amplitudes
indicates the maximal amplitude

Prole view yz

Amax

1 and 2

The distance

b001 c001

of the corrugation.

shows the dierence of amplitude

Since the inclination angles

A of the faces.

They

and interval

of the faces.

are identical, the side fold angles

and

are

identical too (see equation 5.3.6). This can be read in the horizontal view and in the view
of the deployed crease:

a02 b02 b01 = b01 b02 c02 and ad2 bd2 bd1 = bd1 bd2 cd2 .

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

c3

c r3'

c 2'

c 3'

c 1'

a3

F'2

F'4

F4'

b r3'

b 2'

c1
F2

a1
F1

b2

b1

I1
ar3'

a 3'

F'1

F3'

a 3'

a2

b 1'

F'3

R
c2

F4

F3

b3

I2
b 3'

89

y
x

a 1'

F4

F3

a 3r

c 3r

r
3

y
x

c ''2

c 3''
a 3'' F''
4

R''

c 1''

a ''2

F''
3

a 1''

F''
1
d1

d2
b 2''

b 3''

b 1''

A max
2
A max
2

a 1'''

c 1'''

A
max
1

b 1'''

2
r

F3 ''
r
3

b ''

d3

r
3

F3 '''

c 3r ''

a ''

a 3r '''

c d2

c d3

F4

I1

I2

c d1

F2
2

b d3

c 3'''

b 3'''

z
x

F4 '''

b d1

b d2
1
d

F3
a d3

F1
a d2

a d1

y
x

developed
Figure 5.5.7. Reverse fold with non-congruent faces and congruent incli-

nation angles

90

5. REVERSE FOLD

5.5.2.3.

Case 3: reverse fold with unequal inclination angles.

Case 3 (F1 6= F2 , 1 6= 2 , W1 6= W2 , I1 6= I2 , A1 = A2 )
The parameter that is modied in this gure is the inclination angle

in section 5.5.7 the initial crease is composed of two non-congruent faces


gure 5.5.8). If the inclination angle

of face

F2 ,

their amplitude

of face

F1

of the faces. As

F1

and

F2 .

(see

is dierent from the inclination angle

stays constant.

can only be folded up to a certain


side-fold angle which can be found

Folded plate geometries with unequal inclination angles


position. This position is determined by the smallest
on the face with the biggest inclination angle

This has no consequences for solid folded plate structures but it will inuence the way the
folded plate geometry can be oset (see chapter 7).
Folded plate geometries with asymmetric inclination angles cannot be used for deployable
structures.

Symmetric reverse folds We dene reverse folds with congruent inclination


symmetric reverse folds: They are completely foldable.
Asymmetric reverse folds We dene reverse folds with unequal inclination
asymmetric reverse folds: They are not completely foldable.

angles

as

angles

as

The three projection planes show the following characteristics:

Horizontal view xy

The interval

a01 b01

is smaller than the interval

0 0 0
Also, the angle a2 b2 b1 is smaller than the angle
the deployed crease where

is unequal to

variation of the inclination angle

b01 b02 c02 .

b01 c01

as in gure 5.5.7.

This is also visible in

and is a logical consequence of the

Frontal view xz It is identical to the one of gure 5.5.2.


Prole view yz It shows the dierence of the inclination angle and interval I of the faces.
The reverse fold has an asymmetric angle conguration: the inclination angles
as well as the side fold angles

size of the side fold angle

and

In gure 5.5.8

1 > 2

and

and

2 ,

the

, are disparate. For a given bending angle

is inversely proportional to the size of the inclination angle

1 < 2 .

This has a consequence to the foldability of the

max is a function of (see equation 5.3.8).


r
The faces F1 and F3 , with the smaller side fold angle 1 , will attain this position before
r
the faces F2 and F4 . In other words, when closing the reverse fold, the inclination angle 1

comes up to its maximal value


2 before 2 : The reverse fold cannot be completely closed.

reverse fold. Since the maximal bending angle

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

c r3'

c 2'

c 3'

c 1'

F'2

F'4

F4'

c3
a3

I2
b r3'

b 2'

a2

ar3'

a 2'

c1

F2

a1
F1

b2

b1

F'1

F3'

a 3'

F3

b 1'

I1

F'3

c2 R

F4

b3
b 3'

91

y
x

a 1'

F4

F3

c 3r

b3

r
3

y
x

R''
a 3''

F''
3

F''
1
d1

d2
b 2''

b 3''

a 1'''

a 1''

a 2''

b 1''

A/2
A/2

c 1'''

A
1

b 1'''

2
r

F3 ''
r
3

b ''

a 3r '''

z
y

c d2

c d3

F4

c d1

F2
2

b d3

b d2

b d1
1

F3
a d3

F1
a d2

a d1

y
x

F3 '''

a 3r ''

d3

developed

Figure 5.5.8. Asymmetric reverse fold

F4 '''
c 3r '''

b 3 '''

I1

I2

92

5. REVERSE FOLD

Limit of asymmetric reverse fold.

The asymmetry of the face inclination is limited (see gure 5.5.9 and 5.5.10s). A series
of parallel creases, which are positioned parallel to the frontal plane

xz ,

can be bent by

reverse folds without intersection of the faces when the corrugation prole has the following
characteristics:

The inclination

of the corrugation prole edges has to be smaller than

2.

b2 br3 of the reverse fold dene the crease edge


plane M , perpendicular to the reection plane R (see gure 5.5.9). The normal nR to the
r
reection plane R is the interior bisector of the angle b1 b2 b3 . Therefore, the crease edge
plane M can also be dened by the rst segment of the main crease edge b1 b2 , intersecting
the reection plane R at the point b2 , and the normal nR to the reection plane R in b2 .
In our particular case the crease edge segment b1 b2 is parallel to the frontal plane xz , and
5
thus the crease edge plane M is parallel to xz .
The initial faces F1 and F2 have to be on opposite sides of the crease edge plane M . If
r
both faces are on the same side of the crease edge plane M the reected face F4 intersects
r
with the face F1 along the line b2 c4 (see gure 5.5.10). This gure can be represented in a
The main crease edge segments

b1 b2

and

virtual model but not be folded with paper. In order to avoid the intersections of the faces
their inclination angle

has to be limited:

<
5

The normal nR is parallel to the frontal plane xz since the reection plane R is perpendicular to the
frontal plane xz by denition.

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

c3

c 1'''

M'''
a1'''

F4

a3
F3
1

93

c2
c1

a2

F2

b3

b1'''

a1

b2

F1

b1
r

F4'''

F3 '''

nR

c 3r '''

a3r '''

b3r '''

F4

F3

c 3r

b3

x
y

a 3r

Figure 5.5.9. Crease edge plane

c3

c 1'''

M'''
a1'''

F4

a3
F3
1

c2

c1

a2

F2

b3

b1'''

a1

b2

c 4r

F1

b1
r

F3 '''

F4 '''

c 3r '''
a3r '''

nR
b3t '''

F4

F3

b3

z
y

a 3r

c 3r

x
y

Figure 5.5.10. Intersection of an asymmetric reverse fold

94

5. REVERSE FOLD

5.5.2.4.

Case 4: reverse fold with face edges oblique to the crease edge.

Case 4 (F1 = F2 , 1 = 2 , W1 6= W2 , I1 6= I2 , A1 6= A2 , W, I

andA variate)

In this case we modify the geometry of the face edges: they become oblique to the main

crease. The inclination angles

of the faces remain congruent (see gure 5.5.11).

A single crease with skew face edges and the crease edge parallel to the frontal plane
reects o a reection plane
side fold angles

xz

as a crease with face edges parallel to the crease edge. The

are identical: the crease can be completely folded. It can be considered as

a parallel fold whose face edges were cut in a oblique way. However we will rarely use single
creases for folded plate structures. We show this example to underline the importance of
the position of the crease edge relative to the frontal plane
creases edges oblique to the frontal plane

xz .

Section 5.5.3 discusses

xz .

Let us consider a crease formed by faces of changing width (see gure 5.5.11).
edge length of the corrugation prole varies: edge

The

ab is growing and edge bc is diminishing.

The inclination angle of the segments is identical. The developed crease is a parallelogram
with the crease edge

bd1 bd3

oblique to the edges

We place the crease edge

b1 b3

ad1 ad3

and

cd1 cd3 .
xz . As before, the initial
F 4 are reected about it. If

parallel to the frontal view

crease is split by the reection plane

and the faces

F3

and

with parallel folds, crease and face edges were all parallel to the cross section prole, in this
conguration only the crease edge is parallel to it. The inclination angles of the face edges
relative to the reection plane

R vary and thus they reect dierently than the crease edge.

The three views and the view of the deployed crease show the following characteristics :

Horizontal view xy:

The crease edge

b01 b02 b03

is parallel to the

axis. The rst segments of

0 0
the face edges a1 a2 are parallel to each other. The reected segments
b02 br3 0 are not parallel.

Frontal view xz :

a02 ar3 0

and

It shows most clearly the character of the gure. The crease edge reects

o the reection plane parallel to the cross section prole. The face edges have
individual incident and reection angles. As the geometry of the face edges varies
the amplitude of the reverse fold changes. The initial crease is placed such as the
cross section prole represents the mid-line of its maximal amplitude.

Prole view zy

The crease edge is parallel to the x axis, which shows together with the

horizontal view that the reected crease edge forms a plane parallel to the frontal
view. The reected face edges

Developed crease

The side fold angles

a002 ar3 00 and b002 br3 00 appear as


1 and 2 are equal. This

parallel.
shows that, except the

position of the face edges, the gure is identical with a symmetric reverse fold (see
section 5.5.2).

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

95

c 1'
c 2'

I2
c3

a3

c 3'

F'4

F4' c r'
3

b 2'

b 3'

F'2

F3

b 1'

b r3'
r

a 1'

F'1

F3'

F'3

b3

F4

a2

I1

F3

a 3'

F4
r
3

b c

r
3

a'

c1

F2

F1

y
r

a 2'

c2

b2

b1

a1

r
3

a 3r

R''

a 3''

a''2

F''
4

c 3''

F''
3

F''
2

d2

F''
1

b 2''

b 3''

c 1'''

a '''
3

c 1''
c''2

A max
2

d1
a 1''

c '''
2
a '''
2

A max
2

b 1'''

b 1''

c '''
3

a 1'''

max

z
r
3

b '' c ''
r
3

F3 '''

F3 ''

F4 ''

d3

a 3r ''

a 3r '''

F4 '''

b 3 '''

c 3r '''

c d1
c d2

c d3
b

F2

F4

b d2

d
3

2
1

F1

b d1
a d1

F3

a d2
a d3

y
x

developed
Figure 5.5.11. Crease edge parallel and face edges oblique to the frontal

plane

xz

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

5.5.3. Reverse fold oblique to the frontal plane.


edge relative to the frontal plane

xz

97

The position of the main crease

is an important parameter for the geometry of reverse

folds. In this section we investigate main crease edges oblique to the frontal plane

First

xz .

we show the consequences arising out of the oblique position to the frontal plane

xz

for the geometry and the foldability of the reverse fold.

We also show how

oblique reverse folds can be generated by a cross section prole and a corrugation
prole.

Secondly we dene the limits of the rotation relative to the frontal plane xz .
Thirdly we investigate the geometry of multiple reverse folds with the main
oblique to the frontal plane

crease edge

xz .

We investigate a position of the main crease edge oblique to the frontal plane

same conditions as in section 5.5.2: The reection plane

xz

under the

is perpendicular to the frontal

xz , the cross section prole is identical, and the main crease is placed in a horizontal
plane xy . The main crease edge is rotated in the horizontal plane xy with a rotation angle
h . Hereby the bending angle of the projection of the rotated crease edge does not change
plane

a (see gure 5.5.12 and 5.5.13).

and we can use the same cross section prole as before

The rotation of the crease edge relative to the frontal projection plane

xz

has as conse-

quences the asymmetric splitting of the initial crease. The same cross section prole as in
the preceding gures generates a distorted reverse fold. The side fold angles

and

are

unequal and the reverse fold can not be completely closed.

aFor cross section prole edges that are not horizontal, the rotation plan of the crease edge is perpendicular

to the frontal plane and intersecting the corresponding cross section prole edge.

a3

b3

a 2 F3

b2
a1

F1

F4

F2

b1
r

F3

z
y
x

c3
c2

c1

F4

c 3r

b3
a 3r

z
h

xt

yt

Figure 5.5.12. Reverse fold oblique to the projection plane 1

98

5. REVERSE FOLD

The parameter we change in this case is the position of the initial crease relative to
the frontal plane

xz

(see gure 5.5.3). Two congruent faces

position relative to the crease

b1 b3 ,

are rotated in a horizontal

parallel to the projection plane into an oblique position.


Due to the rotation, the reection plane

xz ,

projection plane

F1

R,

F2 ,
plane xy
and

with symmetric
from a position

We call the rotation angle

h .

which remains perpendicular to the frontal

splits the initial crease obliquely to the crease axis

the initial faces are congruent and have the same inclination angle

b1 b3 .

Even though

the split faces are

F3 and F4 about R gives a further rotation to


r
the crease edge b2 b3 relative to the frontal plane xz. The plane M dened by the crease
r
edges b1 b2 and b2 b3 is no longer parallel to the frontal view. To understand this gure we
r
introduce an auxiliary prole plane zy which takes the same rotation as the initial crease.
not congruent. The reection of the faces

This auxiliary prole view is normal to the axis of the initial crease and allows one to see
the corrugation prole in real size. The four views and the view of the deployed crease
show the following characteristics of the oblique reverse fold:

Horizontal view xy

The initial crease

b01 b03

is not parallel to the

h
angle . The reected crease edge

axis but rotated by the

b02 br3 as well as the edges

c02 cr3 0

and

a02 ar3 0

take

a further rotation. They are not superimposing with the initial part of the crease
as in the preceding gures. The length of the edges

Frontal view xz

cross section prole

are unequal.

b001 b2 br3 00 and

The only

c001 c002 cr3 00 relative to the

This view is no more perpendicular to the corrugation prole. It shows the

the initial crease edges

Auxiliary prole view zyr


of the plane

Developed crease
2

c02 cr3 0

d1 d2 d3 .
000 000
a000
2 b2 and b2 c2
000
000 000
a000
1 b1 and b1 c1 .

asymmetric side creases

and

and

this view stays very close to the ones of the preceding cases.

00 00 r 00
alteration is the shift of the edges a1 a2 a3 ,

Prole view zy

a02 ar3 0

in opposition to the symmetric prole of

It shows the corrugation prole as well as the vertical rotation

dened by the crease edge

The angles

and

of the faces are equal.

0000
b0000
1 b2

and

r 0000
b0000
2 b3 .

are unequal even though the inclination angles

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

c'3

99

c r3'
r

b'3

F4'

b r3'

F4'

c'2

a3

F3'

a'3

F3'

b'2

b3

a 2 F3

ar3'

b2
a1

a'1

a 3r

y
x

a'2

b'1

c 3r

b3

F3

z
F1'

F4

b1

c'1

F2'

c1

F2

F1

c3
c2

F4

yt

xt

R''
c''3

a''3

F''3

F''1

d2
b''2

b''3

F''2

d2

F4 ''

b 3r ''

b 1'''

cr3'''

F4 '''

F3 '''
z

r
3

a ''

b 3'''

a 3r '''

c d3

c d2

a 1''''

c d1

A/2
d

F4
d
3

F2

2
d
2

c 1''''

A/2

b 1''''

d
1

F4 ''''

1
d

F3

F3 ''''

F1

a d3

a d2

y
developed

b 3''''

a d1

a 3r ''''

I1

z
x

b 3'''

b 2'''
r

c 3'''
F'''
4

F'''
3

F3 ''
d3

c '''
2

a 3'''

F'''
2

A/2

c 3r ''

c 1'''

a '''
2
F'''
1

A/2

b''1

a 1'''

c''1

a''1

a''2

F''4

I2

yt

Figure 5.5.13. Reverse fold oblique to the projection plane 2

cr3''''

100

5. REVERSE FOLD

Positioning of the simply-corrugated surface

(see gure 5.5.14)

The generation of folded plate geometries with oblique folds (see gure 5.5.14) is similar
to the process described in gures 5.5.3 to 5.5.6.
a)

Generation of parallel creases using the generatrix


as directrix.

In the frontal plane

xz

and the corrugation prole

the generatrix is the mid-line of the outer

edges of the folded plate geometry.


b)

The parallel folds are rotated in plan

c)

Rotation of the generatrix

about

am .

The rotation angle is

am

ab.

z
y
x

h
z

b)

b
a
z

c)

z
x

z
y

y
x

Figure 5.5.14. Folded plate geometry with initial creases oblique to the

projection plane 1

h .

and the folded plate geometry so that the generatrix

superposes the rst segment of the cross section prole

a)

xy

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

Reection o the reection planes

101

(see gure 5.5.15)

The following steps are identical with those described in gures 5.5.5 and 5.5.6 with
the dierence that the main creases of the resulting geometry are not parallel to the
frontal projection plane but approximate a helical form (see gure 5.5.15). For a better
understanding of the helical form generated by folds oblique to the projection plane see
also section 6.1 and chapter 11, gures 11.0.3 and 11.0.4.

c
b

R1

R1
a

a)

c
b

d
z

b)

z
y

c)

R2

R2

z
y

y
x

Figure 5.5.15. Folded plate geometry with initial creases oblique to the

projection plane 2

102

5. REVERSE FOLD

To analyze the consequences of an oblique position of the crease edge, we propose to show
the rotation of the crease edge in a horizontal plane
position oblique to the frontal plane

xz

xy

from a position parallel into a

in a series of gures. The incident crease edge is

h
rotated about a horizontal angle (see gure 5.5.16).
The rotation of the incident crease edge implies a rotation of

M,

the plan containing the

incident and the reected crease edge. The rotation axis is the normal to the reection plane

nR

M determines the position of the faces relative to the crease.


In the original position, with M parallel to the projection plane xz , the two facets F1 and
F2 are symmetric about M . In the oblique position, the rotated facets F1t and F2t are not
t
symmetric about the rotated crease edge plan M . This implies that the inclination angles
t
t
t
of the faces are asymmetric relative to the crease edge plane M : 1 6= 2 . Consequently
t
t
the side fold angles are asymmetric too: 1 6= 2 . As the asymmetric reverse fold, the
. The crease edge plane

oblique reverse fold cannot be completely folded.


In reverse folds parallel to the frontal plane

xz the bending angle of the crease corresponds

to the bending angle of the cross section prole. In reverse folds oblique to the frontal plane

xz

the bending angle

of the cross section prole and the bending angle

of the rotated

t
crease are unequal. The bending angle of the rotated crease grows proportionally to the
h
horizontal rotation of the initial crease edge.

5.5.16 a) The reverse fold is parallel to the frontal plane

zx.

The crease edge

b1 r2

reects

r
o the reection plane and becomes r2 b2 .

R
and parallel to the frontal plane xz . The intersection of the crease edge plane M
with R is g . The normal nR of R is the interior bisector of the bending angle .
c) The incident crease edge b1 r2 is now rotated in a horizontal plane xy . The
h
t
rotation angle is . The frontal projection xz of the rotated segment b1 r2 supert
imposes with the projection of the initial segment b1 r2 . The rotated segment b1 r2

5.5.16 b) The two segments of the crease edge form a plane

5.5.16

that is perpendicular to

is the incident crease edge segment of the crease oblique to the projection plane.

bt1 r2 reects o R and becomes r2 btr


2 . The crease
t
edge plane M has rotated around the normal n. It intersects R in the line g . The
t
t
bending angle opens up: < .
t
e) Shows the angle relation between the incident creases b1 r2 , b1 r2 and the normal
nR of R.

5.5.16 d) The rotated incident crease edge

5.5.16

5.5.16 f ) Shows the oblique reverse fold


With the help of

and

we can dene the bending angle

of the oblique reverse

v
fold and the vertical inclination angle of the crease edge plane M (see gure 5.5.16).
t
Therefore we project a perpendicular to the edge b1 r2 from the point b1 which denes the
t
t
point b3 . The points b1 , r2 , b3 , n1 dene a pyramid composed of four right angled triangles.
This allows us to dene the bending angle

of the rotated crease edge :

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

103

R
g

r3
r1

r2

c1

r2

a1
b1

b1

a)

b)

b2r

c 2r

nR

b2r

a2r

gt

r2

r2
h

b1t
c)

b1

d)

b1t

nR

nR

b2tr
r
2

r5
r4

c 1t

r2

b1

r2

a1t

b1t

f)

b1t

2
e)
nR

nR

b2tr

y
x

a2tr

c 2tr

n1

Figure 5.5.16. Rotation of a reverse fold from a position parallel to a

position oblique to the frontal plane

xz

104

5. REVERSE FOLD

r2 bt3
r2 b1

(5.5.1)

cos(h ) =

(5.5.2)

r2 b1
cos( ) =
2
r2 n1

cos(

(5.5.3)

cos(h )r2 b1 cos( 2 )


t

r2 bt3
=
= cos(h )cos( )
)=
2
r2 n1
r2 b1
2

t = 2 arccos(cos(h )cos( ))
2

(5.5.4)
The bending angle

grows with the horizontal rotation angle

The maximal horizontal rotation angle

t
maximal bending angle max is

h
max

is

2.

h .

The corresponding value of the

This only considers the axis of the crease edge. But the crease is composed of facets.
With a horizontal rotation angle

h
max

the crease edge would be part of the reection plane

and the face on both sides of the plane. Therefore they could not be reected about the

plane.
We call the angle between the fall line of the crease edge plane
the

vertical inclination angle

v of the crease edge plane


sin(h ) =

(5.5.6)

b1 n1

tan( ) =
2
r2 b1
tan(v ) =

. It can be dened as follows:

bt3 b1
sin(h )r2 b1
sin(h )
=
=
b1 n1
tan( 2 )r2 b1
tan( 2 )

v = arctan(

(5.5.8)

and a vertical line,

bt3 b1
r2 b1

(5.5.5)

(5.5.7)

In the next step we will dene the angles

sin(h )
)
tan( 2 )

1t

and

2t

between the main crease and the

side folds. As in gure 5.3.2 the relationship between the bending angle

the inclination

can by established be a plane perpendicular to the

t
crease edge b1 r2 (see gure 5.5.17).

The plane is positioned on the exterior side fold

angles

vertex

and the side fold angles

r5 .

The intersection with

r
crease edge plane M . The point

R is the edge r5 r7 which is also the normal nM


r6 is the intersection of M r and its normal nM .

to the
These

points dene a pyramid with a series of right angled triangles which allows to determine
the side fold angles

1t

and

2t

(see gure 5.5.18) .

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

105

Part b) of gure 5.5.17 shows the oblique reverse fold in a plane perpendicular to its
incident segment

b1 r2 .

The vertical inclination angle of the crease edge plane

The relevant inclination angles

1t

and

2t

are the angles between the normal

faces:

1t = 1 + v = 1 + arctan(

(5.5.9)

sin(h )
)
tan( 2 )

and

2t = 2 v = 2 arctan(

(5.5.10)

sin(h ) v
)
tan( 2 )

Figure 5.5.17. Oblique reverse fold

r7

r5

t
2

r6

t
1

t
2
t
1

r2

b4t
Figure 5.5.18. Angles in oblique reverse fold

Mt

nM

is

v .

and the

106

5. REVERSE FOLD

Equation 5.3.6 gives the relation between the angles


side fold angle

= arctan(

The side fold angles

and

and we can dene the

as follows:

(5.5.11)

stituting

1t

and

2t

tan(
2 )
)
sin

of the oblique reverse fold can be determined by sub-

t
by (see equation 5.5.4) and

respectively

by

1t

and

2t

(see equations

5.5.9and5.5.10)

1t = arctan(

(5.5.12)

tan( 2 arccos(cos(h )cos( 2 )))


h

sin( )
sin(1 + arctan( tan(
))
)

2t = arctan(

(5.5.13)

tan( 2 arccos(cos(h )cos( 2 )))


h

sin( )
sin(2 arctan( tan(
))
)

5.5.3.1.

Limit of oblique reverse fold.

As the rotation of the initial crease edge has as consequence an asymmetry of the facets

M , there is similar to section 5.5.2.3, a limit position for


h . If, for given inclination angle and a given bending

relative to the crease edge plane


the horizontal crease rotation
angle

the crease rotation

is too important, the reected faces intersect the initial

M t . If the
M t , the reected faces F3t r and F4t r do
t
are on the same side of M the reverse

faces (see gure 5.5.19). The limit situation is dened by the crease edge plane
rotated faces

F1t

and

F2t

are on opposite sides of

not intersect the initial faces. If the initial faces


fold intersects itself.
To avoid self intersections the horizontal rotation

of the incident crease edge is limited.

h
If the crease rotation is too important, the reverse fold intersects himself. The limit of
h
the rotation is rapidly attained with strong inclination angles and with small bending
angles

Part a) of gure 5.5.19 shows a self intersecting reverse fold in a projection plane

y t z normal to the incident crease edge segment bt1 r2 . It appears clearly that the vertical
v
t
t
t
inclination angle of M is too big and for that reason the facets F1 and F2 are on the
t
v
t
same side of the crease edge plane M . The vertical inclination angle of M should not
exceed the following value:

v < (

(5.5.14)
By substituting

1 )
2

with equation 5.5.8 we can dene the rotation angle

t
crease edge b1 r2 should not exceed:

the incident

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

arctan(

sin(h )
sin(h )

)
<
(
1

< tan( 1 ) sin( ) < tan( 1 ) tan( )


tan( 2 )
2
tan( 2 )
2
2
2
h < arcsin(tan(

(5.5.15)

M t ''''
c

t
1

1 ) tan( ))
2
2

''''

t
1

''''

gt
r5

F1t

''''
tr

F3 ''''

r4

c 1t

c 3t ''''
t
1

107

a1t

F2

c 3tr

r2

tr

F4 ''''
b1t

tr

tr
2

b2tr ''''

a
c 2tr ''''

F4

''''

tr

F3
nR

b2tr

yt

a)

c 2tr

b)

yt

Figure 5.5.19. Limit of oblique reverse fold

a2tr

108

5. REVERSE FOLD

The bending angle

of the cross section prole and inclination angle

of the corrugation

prole edges inuence the maximal rotation of the incident crease edge. Figure 5.5.20 shows
the relationship of the three parameters: The horizontal axis reports the bending angle

and the vertical axis the horizontal rotation angle

the limit states for given inclination angles

h .

The dierent curves represent

All combinations of bending angles

h
horizontal rotation angles which are situated on the right side of a curve

and

do not

present problems of intersection. We can make the following observations:

are very limitinga. Even with very weak inclination angles


the maximal horizontal rotation angle h is very small.
Strong inclination angles are also very limiting. The curve for = 85 shows
that even for big bending angles the limit value of the horizontal rotation angle
h is rapidly reached.
The biggest limit bending angle for a given inclination angle corresponds to
twice the inclination angle . This constitutes a simple rule which allows one to
h
rapidly estimate if a horizontal rotation angle could be problematic or not.

Small bending angles

It has to be mentioned that the rotation angles

close to the limit curve are also prob-

lematic. Even though the reverse fold does not intersect itself, the faces get very close to
each other and could hardly be built with timber panels.

aWe remind that the bending angle is inversely proportional to the bending of the reverse fold.

90

=3

=10

=20

=30

=45

=85

=60

80
70

maximum horizontal rotation angle

max

60
50
40
30
20
10
0
6

20

40

60

90

120

170

bending angle

Figure 5.5.20. Limit values of the rotation angle

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

5.5.3.2.

109

Multiple oblique reverse folds.

When a geometry is designed by multiple oblique reverse folds, the crease edges and the
corresponding faces continuously rotate relative to the frontal projection plane

xz .

To

understand these positions, we propose to analyze a series of four oblique reverse folds
with a constant bending angle

(see gure 5.5.21). The cross section prole forms half

an octagon. The projections of the crease edges

xz

a00 , b00 , c00 , d00

and

e00

on the frontal plane

are parallel to the cross section prole. The other views show that the edges are not

in a plane but distorted and describe a helical movement (see section 6.1 and chapter 11,
gures 11.0.3 and 11.0.4).
Two adjoining crease edges form a crease edge plan

M.

The inner crease edges

a, b

and

v
dene two crease edge planes M . They are rotated about an angle 2 . Due to the reversion
of the creases, the crease edge planes are always in the same position relative to the faces
(see gure 5.5.22). Thus, in multiple oblique reverse folds the asymmetry induced by the
crease edge does not increase or diminish. The position of the crease edge planes relative
to the faces is dened by the horizontal rotation angle
bending angles

of the rst crease edge and the

of the cross section prole.

To estimate rapidly whether a horizontal rotation angle


to compare the maximum bending angle

is appropriate it is sucient

of the cross section prole and the maximum

max
of the corrugation prole: if
max > 2 the reverse fold will not intersect
v
itself for any horizontal rotation angle . Otherwise the horizontal rotation of the straight

inclination angle

corrugation is limited (see gure 5.5.20).

d
c
e
b

z
y

C
D

d''
C
D
e''

z
x

c''

b''
B
A

a''

A
z
y

Figure 5.5.21. Multiple oblique reverse fold

110

5. REVERSE FOLD

In multiple oblique reverse folds the crease edges form a helix. Two adjacent crease
edges dene a crease edge plane
the plane

Mbc ,

edge

The inner edges

b, c

and

and

M:

a and b dene the plane Mab , edge b and c dene


plane Mcd and edge d and e dene the plane Mde .

edge

dene the

dene two crease edge planes, one with each of their neighbor.

Figure 5.5.22 shows dierent sections perpendicular to one of the crease edges of gure
5.5.21. Column a) shows the section and the elevation of the faces. Column b) shows the
dihedral angle of the faces (the corrugation prole of the crease) and the position of the
corresponding crease edge planes. Column c) shows the position of the obverse and the
reverse part of the crease relative to their common crease edge plane

Section A A

M.

The section is perpendicular to the crease edge segment

a.

The crease edge

v
plane Mab is rotated about the angle (see 5.5.8). Column c) shows the reection
of the corrugation prole about a line normal to the crease edge plane

Mab .

The

reversed corrugation prole corresponds to the position of the corrugation prole


in section

Section B B

B B.

The position of the corrugation prole and the crease edge plane

given from section

Mbc

A A, column c).

Mab

are

The position of the second crease edge plane

Mab
v
about the angle 2 . Column c) shows the reection of the corrugation prole
can be obtained by a counterclockwise rotation of the crease edge plane

about a line normal to the crease edge plane


The same operations are repeated in sections

C C

Mbc .
D D. The corrugation prole
2v at each reversion of the crease.

and

and the crease edge planes are rotated about the angle

The relative position between the corrugation prole and the crease edge plane remains
constant.
If the bending angles
crease edge planes

(see equation 5.5.8).

are constant, as in our example, the rotation angles of the

are constant. Otherwise they vary in function of the bending angles

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

a)

b)

c)
M'ab

M'ab

AA

111

a
b

a'
c
d

BB

b'

M'bc

M'bc

M'ab

M'bc
CC

M'cd

M'cd
c'

y
x

DD

d'
M'de

M'cd

Figure 5.5.22. Relative position of the crease edge plane

112

5. REVERSE FOLD

5.5.4. Limitations of the bending angle.

The value of the bending angle

is

constraint. The limits are dierent for parallel folds than for oblique folds.

Parallel folds

(see gure 5.5.23 a)) A simply corrugated surface with parallel folds must

not be parallel to the reection plane


the plane

R,

- the surface cannot be reected about

-, nor be perpendicular to the reection plane

reected to itself. For parallel folds the bending angle

R,

- the surface is

is limited as follows:

0<<

Oblique folds

(see gure 5.5.23 b)) The edges of simply-corrugated surfaces with oblique

folds are not parallel. In the frontal plane

xz

they form a series of intersecting

lines. We will only consider the general shape and simplify it to two intersecting
lines

and

b.

We call the angle between the two lines the

their intersection we position a reection plane


section prole is the angle bisector of

and

spread angle .

At

across the two lines. The cross

b.

i
The incident edge a must not be parallel to the reection plane
i
the angle between R and a must be greater than zero:

R.

Therefore

(
) >0
2
2
By simplication we can dene:

>
i
The incident edge a must not be parallel normal

nR .

Therefore

<
2
2
The bending angle

of oblique corrugations is limited as follows:

<<
Due to the spread of the main crease edges, oblique folds are more dicult to handle
than parallel folds. If parallel folds can be used with almost any cross section prole

the

form of cross section proles for non -arallel folds is restricted, especially for those with a
wide spread angle

The boundary conditions of cross section lines are described in chapter 6

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

a)

113

b)

R
ai

2
bi

ar

nR

nR
br

ar

Figure 5.5.23. Limitations of the bending angle

bi

114

5. REVERSE FOLD

Consider a series of non-parallel folds generated by two skew lines


length as shown in gure 5.5.24. The lines

and

and

of equal

are are elements of two parallel planes

and divided in four equal segments linked by straight lines which form four non-planar
quadrangles. In order to obtain planar faces we connect two opposite ends of each quadrangle by a diagonal. We now have a developable poly-surface composed of non-parallel
folds which approximate a ruled surface .
A reection plane

R,

parallel to the planes that contains the lines

pendicular to the mid-segment


plane

a3 b3

that connects

and

b,

and

b,

and per-

reects the poly-surface o the

(see 5.5.24). It is evident that the reected surface intersects the initial surface.

a3 b3 such as the faces


r
adjoining a3 b3 reect back to themselves. The reected line b intersects a and so does the

The normal to the reection plane

nR

is parallel to the segment

poly-surface generated by the two lines. The incident crease edge segments are situated on
both sides of the normal to the reection plane

nR

(see frontal view) and as a consequence

the reected crease edge segments cross themselves.

This is a clear indication that the

reected poly-surface is intersecting itself. If we analyze the crease line of the side folds
in the undeployed poly-surface we can see that the side fold angles

next to the middle

d d
segment a3 b3 , are
2 . Normally, the side-folds are a sequence of alternating concave and
convex folds. In this case side-folds next to the middle segments are neither convex nor
concave. This singularity in the sequence of side-folds is also an indication that the surface
cannot be physically folded and will intersect itself.

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

b
b'

a'

b'3

a'3

b3

a
R

b' r

115

a3

z y

R''

b''

b'' r
a''3

b''3

a'''
3

nR
a''

a'''

b'''
b'''
3

b'''r

z
y

+
d
3

+/-

a3d

+
+

z
x developed

Figure 5.5.24. Ruled surface, reection about a plane parallel to the

generating lines

116

5. REVERSE FOLD

By changing the the inclination of the the reection plane

a3 b3 ,

relative to the mid-edge

the intersection of the poly-surface is moved away from the mid-edge. The reected

and the initial poly-surface intersect in a line instead of a surface, like in gure 5.5.24.
Again the incident crease edges are situated on the left and on the right side of the normal
to the reection plane

nR

and the reected edges cross each other. By isolating the faces

that intersect themselves and showing them in a axillary view, perpendicularly to the
corresponding crease edge, we can see that the crease edge plane

is situated outside

the angle dened by the corrugation prole (see section 5.5.3.1). The angle between the
normal of the reection plane

nR

and the incident crease edge is very small and therefore

the reversed fold intersects itself even though the rotation of the incident crease edge

is

weak (see gure 5.5.20). In the deployed surface, close to the intersection of the surface, the
sequence of side-folds shows two concave folds instead of alternating convex and concave
folds.

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

b
b'

a'

b'3

a'3

b3

a
R

b' r

117

a3

z y

R''

b''

a''
a''3

b''3

a'''

b'''
a'''
3

b'''
3

nR
z

b'' r

b'''r

z
y

a''''
d

b''''

b'''' r

a''''
3

+
-

b3d

+
+

z
x developed

a3d

b''''
3
M''''

z
y

Figure 5.5.25. Ruled surface, reection about a plane oblique to the

generating lines

118

5. REVERSE FOLD

To avoid the intersection of the reected poly-surface with the initial poly-surface the
position of the reection plane

R has to be chosen carefully (see gure 5.5.26 and appendix,

gure 11.0.11). The angle between every incident crease edge and the reection plane R
must be smaller than
of the normal

n00R

2 . When all incident crease edges are positioned on the same side

they do not cross each other as in gure 5.5.24 and 5.5.25.

The side-folds in the deployed poly-surface show the normal succession of concave and
convex creases.

5.5. REVERSE FOLD IN ORTHOGONAL PROJECTION

119

b
b'

a'

b'3

a'3
b' r

R''

a3

b''

a''

a'''
3

b'' r

b'''
3

nR
x

a'''

b'''

a''3

b''3

b3

b'''r

+
-

b3d

+
-

a3d

+
-

z
x developed

Figure 5.5.26. Ruled surface, reection about a plane oblique to the

generating lines

120

5. REVERSE FOLD

5.5.5. Amplitude variation.

In a straight parallel fold the amplitude is constant.

Bending the crease by reverse folds modies the amplitude in the reecting zone (see gure
5.5.27). The amplitude of the corrugated surface varies locally. The strongest modication
is perpendicular to the reection plane
section prole edges

and

along the interior angle bisector of the cross

b:
Amod = kA
1
2 sin( 2 )

k=

and the factor k .

Figure 5.5.28 shows the relationship of the bending angle


7

For small

60
k = 0, 5.

bending angles the amplitude increases in the reecting zone . With a bending angle of
the amplitude stays constant. If

> 60

the amplitude decreases rapidly until

For Folded plate structures we will mainly use bending angles between 90 and 150 which
signies that the amplitude is diminished by a factor

k = 0, 7

0, 5.

to

The diminished amplitude is balanced by the fact that in the reecting zone the number
of folds is increased.
7

The size of the bending angle is inverse to the bending of the fold.
mab

f2

iab

e2

f1

e3
A
2

A mod
b
ief

f3

e1

Figure 5.5.27. Relation between opening angle

and factor

factor k (-)

2
1.93

1.00
0.71

0.58

0.52

0.5

0
0

30

60

90

angle

120

150

180

()

Figure 5.5.28. Relation between bending angle

and factor

5.6. DISCUSSION

121

5.6. Discussion
The reverse fold is a reection of a straight crease about a plane. It can be generated
by two lines:

Corrugation Prole It denes the geometry of straight folds.


Cross Section Prole It denes the bending angle of the reverse
reected about a plane

fold. The creases are

R dened by the exterior angle bisector of the cross section

prole.
The cross section prole and the corrugation prole are sucient to dene the geometry
of folded plate structures.

The proposed method is simple and enlarges the possibility

of reverse fold geometries in regard to paper folding.

It is interesting to note that the

geometries of asymmetric and oblique reverse fold cannot be obtained by the classic method
of paper folding where the crease has to be completely closed. The method is limited to
the bending of straight creases. Other types of four edge vertices, such as the rabbit ear
fold, cannot be generated by this method.
The conditions that limit the reverse fold have been dened. Two pairs of parameters
dene the nature of the reverse fold:

Symmetry - asymmetry

M.

The edges of the bent main crease form a plane

of the crease are symmetric to the plane

If the faces

the reverse fold can be completely

closed. As a consequence the edges of a corrugation prole must have identical


inclination angles
fold.

in order to be completely foldable when bent by a reverse

If the inclination angle

asymmetric relative to the plane

of the corrugation edges varies, the faces are

and the reversed crease cannot be completely

folded. Even though the aim of the present research is the construction of solid
structures, the distinction between symmetric and asymmetric structures might
be useful for deployable structures.
The asymmetry of a corrugation prole is limited: the inclination angle

of

its edges must be smaller than . Otherwise the faces of the reverse fold intersect
2
themselves.

Parallel - oblique

The position of the crease edge relative to the frontal plane

the position of the crease edge plane

xz .

xz ,

is not parallel to the frontal plane

If

are symmetric

of the corrugation prole edges are

equal. If the initial crease edge is oblique to the frontal plane

the crease edge plane

In this case the side fold angles

under condition that the inclination angles

plane

inuences

and the size of the side fold angles

the initial crease edge is parallel to the frontal plane


is parallel to the frontal plane

xz

xz .

xz ,

the crease edge

The side-folds angles

become

asymmetric and the reversed fold cannot be completely closed. A single oblique

M , but in a series of oblique reverse


M varies in function of the bending

fold can be symmetric to the crease edge plane


folds the inclination of the crease edge plane
angle

and oscillates between concave and convex folds.

CHAPTER 6

Geometries based on reverse fold in orthogonal projection


In this chapter we will describe the generation of folded plate geometries by multiple
reverse folds (see gure 6.0.1). They are dened by a corrugation prole and a cross section
prole. The geometry of one prole is constraint by the geometry of the other prole.

First
Secondly

We outline the possibilities of shaping the general form of these geometries.


We show how the geometry of the cross section prole determines the pattern
of the folded plate geometry.

Thirdly

We describe the limit states of the two main patterns and how they modify,
vertex and pattern type.

6.1. Macro-form of folded plate geometries


When describing the form of a folded plate geometry we can distinguish the form as a
whole, the macro-form, and the geometric units that compose the overall form, the microform [

Sed75a].

The macro-form describes the general form of a folded plate geometry. The

Figure 6.0.1. Curved folded plate geometry


123

124

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

macro-forms of folded plate geometries consisting of a single, continuous, and developable


surface, generated by a corrugation and a cross section prole, are strongly constrained.
A simplied macro-form can be drawn by replacing the corrugation prole by its midline, (see section 4.2) which outlines the general shape of the corrugation prole (see gure 6.1.1). The corrugation mid-line is then extruded and the resulting surface reected
about the reection planes given by the cross section prole. The resulting surface only
shows the bending of the folded plate geometry without its corrugation. The latter can
be designed in order to respond to specic requirements, for example, to give a certain
structural stiness. The simplied macro-form shows the general envelope of the folded
plate geometry. It is the mid-surface around which the folds oscillate.
Three parameters inuence the shape of the macro-form:

The cross section prole.


The shape of the corrugation mid-line.
The position of the simply-corrugated surface relative to the frontal plane

Cross section prole

xz .

The macro-form is mainly determined by the cross section pro-

le. There exists great freedom for the design of the cross section prole. Its shape can
be adapted in order to respond to architectural, structural, functional and constructive
constraints. For example the cross section prole can be designed such that vertical loads
are directly transmitted to the ground. Its shape can also be adapted to a spatial prole
required for a given program. Further the slope of a roof can be controlled by the cross section prole in order to drain the rain water. The cross section prole strongly characterizes
the form and space of the folded plate structure.

Shape of the corrugation mid-line The shape of the corrugation mid-line denes whether
the macro-form is a straight cylinder surface or whether this cylinder surface is locally
deformed. If the corrugation prole mid-line is a horizontal straight line, the macro-form
1

is a cylinder surface

(see 6.1a)) . The type of form is therefore limited to singly-curved

surfaces whose longitudinal section is invariable. This restricts the formal possibilities of
folded plate geometries.
In principle, all macro-forms of the proposed geometries are approximations of cylinder
surfaces. But, there exists a certain freedom of variation around the straight cylindrical
form.
If the corrugation mid-line is curved, a poly-line, or sloped, the macro-form varies (see
gure 6.1.1 b-d)). The corrugation mid-line can take dierent forms but has to progress
forward in every point, otherwise the reected surface creates self intersections (see section
5.5.2.3).

A cylinder surface is dened by a prole which is extruded in some direction by parallel extrusion
[PAHK07].

6.1. MACRO-FORM OF FOLDED PLATE GEOMETRIES

Position relative to the frontal plane xz

125

As discussed in chapter 5 the position of

the simply-corrugated surface inuences the shape of folded plate geometries.


corrugated surfaces parallel to the frontal plane

xz

Simply-

have a cylinder shape. For a simply-

corrugated surface oblique to the frontal plane, the bent surface has an helical shape. All

xz .
y axis the variations of the macro-form

types of corrugation mid-lines can be used for an extrusion oblique to the frontal plane
Due to the helical extension of the surface along the
becomes less explicit.

126

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

Figure 6.1.1 shows how the shape of the corrugation mid line and the position relative
to the frontal plane

xz

inuence the macro-form. The cross section prole is the same for

all gures: a hexagon.

The rst column shows the shape of the corrugation mid-line.


The second column shows the corresponding macro-forms when the initial surface is
parallel to the frontal plane

The third column


plane

xz.

shows the macro-form when the initial surface is oblique to the frontal

xz .

Within the following we briey comment the gures of the second column.
6.1.1 a) The corrugation mid-line is straight and horizontal. The macro-form is a hexagonal prism.
6.1.1 b) The corrugation mid-line is a slightly sloping straight line. Basically it is a single
inclined face that is reected about the reection planes dened by the hexagonal cross section prole.

The cross section of the resulting gure varies from a

truncated triangle standing on its base to a truncated triangle standing on its


2

top .
6.1.1 c) The corrugation mid-line is curved.
evolves along the

axis.

As in the preceding gure the macro-form

Observing the resulting gures it is interesting to see

that one can generate curved creases. Not only, the corrugation mid line but also
the corrugation prole could be curved. The generated surfaces are developable as
those which are composed of straight creases (see appendix gures 11.0.9, 11.0.14,
11.0.16). This opens new perspectives for applications with other materials than
cross-laminated timber panels.
6.1.1 d) The corrugation mid-line is a poly-line composed of two edges. The macro-form is
constituted by six reverse folds. It demonstrates that the dierence between the
generation of a macro-form and the bending of a straight creases is just a matter
of scale.

The macro-form has a strong resemblance to a triangular anti-prism. It is interesting to note that most of
the folded plate geometries proposed for structural applications are based on anti-prisms [Sed75a, KR78,
Huy99, Fro78].

6.1. MACRO-FORM OF FOLDED PLATE GEOMETRIES

(a)

z y
z

(b)

z y
z

(c)

z y
z

(d)

z y
z

Figure 6.1.1. Macro-forms of folded plate geometries

127

128

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

(a)

z y
z

(b)

z y
z

(c)

z y
z

(d)

z y
z

Figure 6.1.2. Folded plate geometries corresponding to the macro-forms

of gure 6.1.1

6.1. MACRO-FORM OF FOLDED PLATE GEOMETRIES

129

Folded plate geometries corresponding to the macro-forms of gure 6.1.1 are shown in
gure 6.1.2. The corrugation mid-line is replaced by a corrugation prole. The contrast
between the form generated with a curved (see gure 6.1.2c) and polygonal (see gure
6.1.2d) corrugation mid-line is lessened by the creases.
Macro-forms with altering cross sections along their longitudinal axis are interesting
to create spaces with varying width and height. This is most eective with simple cross
section proles composed of only a few edges. Figure 6.1.1b) shows that a compression in
one direction always results in a decompression in the opposite direction. A short edge of
the cross section line is next to two long edges and alters to a long edge next to two short
edges. The slope of two adjoining faces is inverted. This is eective as long as the variation
of an element is signicant relative to the scale of the macro-form. Shapes generated by
cross section proles with many edges allow only small variations of the macro-form that
become insignicant. This eect is reinforced when the macro-form gets corrugated. The
alternation of concave and convex creases makes it dicult to read a clear reference surface
and therefore blurs small variations of the macro-form.

The macro-form of the proposed folded plate geometries is essentially a cylinder surface
which is simply-curved and has a strong orientation along the longitudinal axis.
shape is mainly given by the cross section prole.

The

Longitudinal variations of the form

can be introduced by a shape variation of the corrugation mid-line.

The amplitude of

these variations is limited. They are particularly interesting for cross section proles with
few edges (see appendix, gures 11.0.1, 11.0.9, 11.0.10, 11.0.12, 12.2.1). The macro-form
can get a helical shape by using a corrugation prole extruded obliquely to the projection
plane.
The use of macro-forms is an ecient way to visualize the general shape of a folded plate
geometry without modeling the details of the corrugation (see chapter 9, gure 9.2.1 and
appendix, gure 12.2.1).

130

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.2. Cross section prole and pattern types


The cross section line does not only outline the general form of the folded plate geometry
but its shape also determines the pattern of the developed surface.
The appearance of a simply-corrugated surface is strongly characterized by a series of
concave and convex folds, represented by the corrugation prole. We called these straight
creases the main-folds which form a main corrugation of the surface.
By bending a simply-corrugated surface with a series of reverse folds, a secondary
corrugation of the surface is introduced. It runs across the main corrugation and takes the
shape of side-folds, oblique to the main-folds. The secondary corrugations are dened by
the cross section prole (see gure 6.2.1).

The proposed folded plate geometries are doubly-corrugated surfaces.

Their pattern is

dened by two proles:

corrugation prole

It denes the main corrugation, composed of straight main-folds.

cross section prole

It denes the secondary corrugation, composed of side-folds oblique

to the main-folds.

The unfolded pattern of the main corrugation is composed of parallel or slightly oblique
lines. It is very similar for all doubly-corrugated surfaces and thus not very character giving.
The secondary corrugation imprints a specic character to the main-fold pattern. The sidefolds reveal the shape of the main corrugation. By cutting across a series of straight folds
and reecting them, the side-folds design a skewed shape of the corrugation prole (see
gure 6.2.1).
As for the corrugation prole, the cross section prole is a poly-line with convex and
concave vertices. The order of convex and concave vertices characterizes the cross section
prole.

6.2. CROSS SECTION PROFILE AND PATTERN TYPES

Main folds

y
x Developed crease pattern

z
y

Side folds

z
x

Secondary corrugation: cross section profile

Main corrugation: corrugation profile

Figure 6.2.1. Primary and secondary corrugation

131

132

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.2.1. Side-fold orientation and direction.

The cross section prole represents

the bending of straight main-fold. Side-folds are formed in the reection plane

R.

Side-

folds and main-folds form a 4-degree vertex with one concave and three convex folds or the
inverse, three concave and one convex fold [

Huf76].

The principle of the reverse fold is

that the orientation of the main-fold is inverted: it always changes from concave to convex
or vice versa. Thus both side-folds are either concave or convex. Their orientation depends
on the change of direction of the main-fold, represented by the cross section line.

en and en+1 (see gure 6.2.2 A


angle which corresponds to a

Consider a cross section prole composed of the edges

B ).

and

The edge

en+1

is rotated clockwise about the

convex cross section prole vertex. The resulting side-folds are convex folds independently
of the main-fold orientation.

Vice versa the side-folds are concave if the edge

turning counter-clockwise (see gure 6.2.2

and

en+1

is

D).

The side-fold edges form an arrow shape. The arrow direction depends on the mainfold orientation.

In gure 6.2.2 A and B, the side-fold orientation is convex.

The rst

main-fold edge of gure 6.2.2 A is convex and the side-fold arrow points to the left. The
direction of the arrow is inverted if the rst main-fold edge is concave (+) (see gure
6.2.2

B ).

Figures 6.2.2

and

show the same phenomena with inverted signs. If the

orientations of the rst main-fold edge and the side-folds are equal, the arrow points to
the left:

m , s and m+ , s+ = <

. The arrow points to the right when the orientations of

the rst main-fold edge and the side-folds are unequal:

m , s+ and m+ , s = >

In the present example the four polyhedral surfaces are congruent and can be trans-

A can be transformed into B and C into D by rotation around the


normal to the reection plane nr . A can be transformed into C and B into D by rotation
around a horizontal axis x. This means that C and D can be considered as the bottom
view of A and B .
formed into each other.

The orientation of the crease is relative and depends on a convention.

As for the

corrugation prole, we dene that in a cross section prole, the edges are denoted from
the left to right.

If the rotation from

en

to

en+1

is negative (clockwise rotation), the

corresponding side-folds are convex (-). The side-folds are concave (+) if the rotation from

en

to

en+1

is positive (counter-clockwise rotation).

corrugation prole determines the orientation of the main-folds. The cross section
prole determines the orientation of the side-folds. Positive rotation of the cross section
The

edges results in concave side-folds, negative rotation in convex side-folds. The direction of
the arrow formed by the side-folds depends on the orientation of the main-fold.

6.2. CROSS SECTION PROFILE AND PATTERN TYPES

133

nR

y
x

nR

en+1

+
nR

+
en

en

z
x

A'', (B'')

nR
C'', (D'')

en+1

s+

sms-

Ad

m-

m+

s+

Dd

s+

sm-

m+

m+

m-

m+

y
x

developed

Bd

s-

Figure 6.2.2. Side-fold orientation

s+

134

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.2.2. Cross section prole and basic pattern types.

The patterns of doubly-

corrugated surfaces are determined by their main-fold orientation and their side-fold orientation.

Hereby we consider that the main corrugations are composed of alternating

concave (+) and convex (-) folds. Such main corrugations correspond to the patterns of
paper folding and present characteristic qualities which can be extended to patterns based
on other main corrugations.
Two types of cross section proles which two basic patterns:

convex polygonal cross section prole


zig zag polygonal cross section prole

Convex polygonal cross section prole


same direction (see gure 6.2.3).

All edges of the cross section prole turn in the


3

The orientation of the vertices is always convex .

All

side-folds are convex. Their arrow direction alternates due to the alternating orientation
of the main-fold. The resulting pattern is composed of quadrilaterals. They are trapezoids
except for main corrugations with oblique folds, where the parallel sides of the trapezoids
are skewed. This basic form is copied by rotation along the

axis and reected about the

main-fold . Hexagonal pattern, Diamond pattern and, within certain restrictions, diagonal
pattern, presented in chapter 3, are based on convex polygonal cross section lines (see
appendix gures 11.0.1, 11.0.3, 11.0.4, 11.0.5, 11.0.6, 11.0.9, 11.0.10, 11.0.11, 11.0.12). To
create these dierent patterns the geometry of the basic quadrilateral has to be modied
(see section 6.3). Note that all convex folds are on one side of the cross section prole and
all concave folds on the opposite side.

The orientation of the vertices could also be constantly concave but for covering spaces with folded plate
structures we will mainly use cross section proles with convex orientation.

6.2. CROSS SECTION PROFILE AND PATTERN TYPES

135

x
-

+
-

z
x

y
x

developed
Figure 6.2.3. Convex polygonal cross section prole

136

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

zig-zag polygonal cross section prole

The vertex orientation between two edges of the

cross section prole alternates from convex to concave and so do the side-fold orientations
(see gure 6.2.4). In contrast to this, the arrow direction of the side-folds does not change.
Again, the pattern is composed of quadrilaterals which are trapezoids. The position of the
main-fold edges is shifted so that the side-folds edges are inclined in the same direction.
This basic form is copied by rotation about the

axis and reected about the main-fold.

The herringbone pattern is based on a zig-zag polygonal cross section prole (see appendix
gures 11.0.6, 11.0.7, 11.0.13, 11.0.14, 11.0.15). Variations of this pattern and constraints
are discussed in section 6.3.

Again all convex folds are on one side of the cross section

prole and all concave folds on the opposite side.

6.2. CROSS SECTION PROFILE AND PATTERN TYPES

137

x
-

y
x

developed
Figure 6.2.4. Zig-zag polygonal cross section prole

138

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

Variations of cross section prole types

Convex and zig-zag polygonal cross section

proles are the two most typical cross section proles. The rst one is based on side-folds
with alternating arrow directions (< >), and the second one on side-folds with unchanging
arrow direction (< <). Dierent folding patterns can be created by combinations of these
two basic types (see gure 6.2.5 and appendix, gures 11.0.2, 11.0.17, 11.0.18).

Each

pattern is characterized by a cross section prole with a specic series of concave and
convex vertex orientations. The constraints for each of these patterns can be derived from
the constraints of the two main cross section proles described in section 6.3.

+
-

+
-

Figure 6.2.5. Variations of cross section prole types

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

139

6.3. Limit conditions of cross section and corrugation prole


6.3.1. Convex polygonal cross section proles.
line can be used as a cross section prole.

Principally any convex polygonal

However, to each cross section prole will

correspond a maximum amplitude which the amplitude of the corrugation prole should
not exceed and that will limit the eective depth of the folded plate structure. It is therefore
important to know on which parameters the maximum amplitude depends. Furthermore,
it is useful to control the design of a cross section prole in order to respect a chosen
amplitude of the corrugation prole.
6.3.1.1.
edges

Maximum amplitude.

a,b,c and d (see gure 6.3.1).

Let us consider a cross section prole composed of fourThe exterior angle bisector of two edges can be designed

by help of their extension.


We now place a simply-corrugated surface with a constant amplitude
edge

such that the

is the mid-line of the corrugated surface, and reect the surface o the reection

planes represented by the exterior angle bisectors

Rab

For simplication, we only discuss the frontal projection


main-fold edges,
it.

A,

and

f,

Rbc , and Rcd (see gure 6.3.2).


xz . We then have two polygonal

one on each side of the cross section prole and equidistant to

Their vertices are located on the external angle bisectors.

The main-fold edges are

R bc

R ab

a
z
x
Figure 6.3.1. Construction of the cross section prole

R cd

140

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

composed of alternating long and short edges parallel to the cross section prole.

For

e1 e2 is long, e2 e3 short, e3 e4 long and e4 e5 short. The order of long


and short edges in f is inverted. Increasing the amplitude A of the corrugation prole will
stretch out the long edges and reduce the short ones. The maximum amplitude Amax of a
example: the edge

given cross section prole is reached when a main-fold edge is reduced to a point.
Figure 6.3.2 a) and b) show the same cross section prole. The corrugation amplitude
is increased in gure b). The vertices

e2 and e3 shift on the external angle bisectors Rab and

Rbc until they collide at the intersection of the angle bisectors. The maximum amplitude
Amax of the cross section prole corresponds to twice the distance between the cross section
prole and the intersection of the external angle bisectors. In an arbitrary cross section
prole, as in gure 6.3.2, this distance varies for each edge of the cross section prole. It
is then the shortest distance between a cross section prole edge and the corresponding
external angle bisector intersection, which determines the maximum amplitude

e3

e2
a)

R ab

R bc

Amax .

f3
f4

R cd
e4

f2
d

a
f1

e5

A
2 A
2

f5

e1

R bc

e2 e3

f3
f4

b)

R ab

A max
c

R cd
e4

f2
f1
A
2
z

e1

f5

e5
A
2
x

Figure 6.3.2. Maximum amplitude for a given convex cross section prole

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

6.3.1.2.

Vertex type and pattern.

141

The amplitude of the corrugation prole inuences

the valence of the vertices and the pattern of the folded plate geometry. Figure 6.3.3 shows
the developed patterns and axonometries of gure 6.3.2.

Normal amplitude

(see 6.3.3 a)) All vertices have four-edges:

two convex side-folds

edges as well as of a convex and a concave main-fold edge. The pattern is composed of
quadrangles. The convex creases design an irregular hexagonal pattern.

Maximum amplitude

(see 6.3.3 b)) The second pattern is composed of triangles and

quadrangles. The second row of the pattern is composed of triangles: two four-edge vertices
with opposite arrow directions touch each other and form a six-edge vertex composed by
four convex side-folds and two concave main-folds. The convex side folds form a kite .

If the maximum amplitude is reached, the valence of the vertices changes: at the exterior angle bisectors intersection which determines the maximum amplitude, two four-edge
vertices unify into a six-edge vertex. The corresponding side crease pattern changes from
hexagon to kite form.

a)

x
y developed

y
x

b)

Figure 6.3.3. Inuence of corrugation amplitude on the pattern

142

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.3.1.3.
bisectors

In-circle.

Rab

and

Rbc

Three cross section prole edges

ob

as well as their intersection

between the middle edge

a, b

dene two exterior angle

(see gure 6.3.4 a)). The distance

and the bisector intersection

plitude of the cross section prole for the edge

and

ob

determines the maximum am-

b:

Amax b = 2 bob
The extension of edge

and

form a triangle with edge

is equidistant to the three triangle edges

Iabc

a, b and c.

b.

The bisector intersection

It is actually the center of the in-circle

, the unique circle which is tangent to all three sides of the triangle

The center of an in-circle


bisectors of the triangle

abc

ob

abc5.

is dened by the intersection of the three interior angle

(see gure 6.3.4 b).

Convex polygonal cross section prole - in-circle


To each cross section prole edge, except to the rst and the last one, corresponds an incircle tangent to the edge. We can now dene the maximum amplitude of a cross section
prole as follows:

I
Amax = 2rmin
where

I
rmin

is the smallest in-circle radius of the cross section prole.

Vertex conguration and pattern design of convex polygonal cross section proles can be
controlled by the in-circle radius.

If the radii of all in-circles are congruent all vertices

will have six-edges for a main corrugation with constant amplitude corresponding to twice
the in-circle radius. The pattern will be composed of kites or rhombuses (see appendix,
gures, 11.0.3, 11.0.4, 11.0.5). The in-circle radius is also useful to guarantee a minimal
amplitude

Amin

for every inner cross section prole edge (see chapter 9, gure 9.2.2).

With convex polygonal cross section proles the in-circle is only tangent to one of the edges of the cross
section prole and tangent to the extension of the two adjacent edges. We therefore name the in-circle
with the sign corresponding to the cross section prole edge tangent to it. For example in the present case,
the in-circle of the edges abc is called Ib .
5
The exterior angle bisectors of a cross section prole abc are the center of the in-circle as long as the sum
of the angles enclosed by the edges ab and bc is bigger than 2 . If the sum of the angles is smaller than 2
the exterior angle bisector intersection becomes the center of the ex-circle (see section 6.3.2.3). It signies
that the three cross section prole edges form a triangle on their concave side, which is very rare in the
convex polygonal cross section proles we use.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

a)
ob

Ib

Ic

R bc

oc

I
c

I
b

R ab

R cd

z
x

b)
a

2
I abc

oabc

2
rI

2
b
Figure 6.3.4. In-circle

143

144

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.3.1.4.

Convex cross section proles of constant amplitude.

Based on the in-circle we

can design a cross section prole of constant amplitude (see gure 6.3.5).
6.3.5 a

We dene a rst edge

6.3.5 c

6.3.5 d

and a point

oa

which is the center of the in-circle and

a. The radius raI corresponds to half the maximum


amplitude Amax . We design a second edge b of the cross section prole tangent to
the in-circle Ia . The direction of b can be chosen arbitrarily as long as b is tangent
to Ia and intersect a (see 6.3.5 b)).
Once edge b is xed, we can dene the exterior angle bisector Rab of the edges a
and b. The length of Rab is dened as follows : oa iab = iab ob . The symmetry of
the in-centers oa and ob about the edge intersection iab ensures that the radii of
I
I
the in-circles Ia and Ib are constant: ra = rb .
We now have dened two cross section prole edges a and b, a rst angle bisector
Rab and two in-circles Ia and Ib . The third cross section line edge c is tangent to
Ib . Again, its direction can be chosen arbitrarily as long as c is tangent to Ib and
intersect b.
draw the in-circle

6.3.5 b

Ia

tangent to

The construction steps a), b) and c) are repeated until the entire cross section
prole is drawn.

Every new edge must be tangent to the in-circle dened by

the two preceding edges. All in-circles are congruent and the angle bisectors are
symmetric about the edge intersections.

If we want the cross section prole to be a regular polygon the distance between the cross section vertices
i and the in-circle centers o has to be constant.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

145

ob
rbI
b

i ab
R ab

oa

raI

I
oa ra

a)

b)

ob
I
b

iab
R ab
I
oa ra

c)

ob
rbI
b

i ab

R bc

oc

ibc
rcI
c

R cd
icd

rdI

R ab
I
oa ra

d)

d
a

Amax = 2r I

Figure 6.3.5. Design of convex cross section prole with constant maxi-

mum amplitude

od

146

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

Simplied method

The method used to design a cross section prole can be simplied.

It is not necessary to draw the in-circle. We can reect the cross section prole edges about
a line that originates in the in-circle center (see gure 6.3.6):

6.3.6 a) We draw a rst cross section prole edge


to
in

a
oa

oa

at a distance

about an axis originating

and whose direction can be chosen arbitrarily under the condition that it

intersects the edge


edge

and dene a point

1
that corresponds to Amax . We reect the edge
2

a.

The reection of

provides the second cross section line

b.
a and b is dened by their intersection
The second in-circle center ob is element of Rab and at the same distance

6.3.6 b) The exterior angle bisector

iab and oa .
to iab as oa .

6.3.6 c) The next edge


intersecting

b.

Rab

is created by a reection of

6.3.6 d) The third in-circle center

ibc

about a line originating in

o2

and

Again the direction of the reection line can be chosen arbitrarily

under condition that the edges

distance to

of the edges

as

ob .

oc

a, b

and

ob .
bisector Rbc

form a triangle enclosing

is element of the exterior angle

at equal

By repeating the aforementioned construction steps we can

complete the cross section prole.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

147

ob
b

i ab
R ab

oa

oa

b)

a)

ob
b

i ab
R ab
oa

c)

i ab

oa

ibc

oc
R cd
c

icd

od

R ab
d)

R bc

ob

d
a

z
Amax = 2 oaa

Figure 6.3.6. Simplied design of convex cross section prole with con-

stant maximum amplitude

148

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

Figure 6.3.7 shows a developed and a folded surface corresponding to the cross section
prole drawn in gure 6.3.5. All vertices have six-edges and the faces in the inner pattern
rows are triangles. The frontal view shows the face edges intersecting the in-circle centers.
The face edges

e2 e3

and

f3 f4 ,

parallel to the edges

and

of the cross section prole,

have shrunken to a point. This conguration corresponds to the

diamond pattern.

With

the same cross section prole but with a smaller corrugation prole amplitude, the pattern
would be composed of quadrangles and correspond to the
6.3.3).

hexagonal pattern (see also gure

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

x
z

149

y developed

ob (e2e3) Rbc ibc

i ab

oc (f 3 f 4 )
c

Rcd
icd

Rab
oa(f2 )

od (f4 )

f1

e2
e1

Amax

f2

z
x
Figure 6.3.7. Convex folded plate geometry with constant maximum amplitude

150

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.3.1.5.

Plus Ultra: beyond maximum amplitude.

For folded plate structures we gen-

erally use geometries where the amplitude of the corrugation prole is smaller or equal to
the maximum amplitude of the cross section prole:

I
Amax 5 2rmin
When the maximum amplitude of the corrugation prole is smaller than the maximum
amplitude of the corrugation prole the folded plate geometry is composed of quadrangles.
When the maximum amplitudes of the two proles correspond and the in-circle radii of
the cross section prole are constant, the folded plate geometry is composed of triangles
(see sections 6.3.1.2 and 6.3.1.4).
However it is possible to generate geometries where the maximum amplitude of the
corrugation prole exceeds the maximum amplitude of the cross section prole:

I
Amax > 2rmin
Let us consider a convex cross section prole with three edges

a, b

Rab and Rbc (see gure 6.3.8). A crease


I
2rb reects o the reection plane Rab to form F3 and F4 (see gure

corresponding exterior angle bisectors


an amplitude

A>

6.3.8 a) and b)). In the front view

xz , the crease edge e1 e2

intersects the angle bisector

This signies that in 3-dimensional space the side-folds and the faces
the next reection plane

and

F8

F1

and

F2

Rbc .

intersect

Rbc .

In the next step all four faces reect o the reection plane

F5 , F6 , F7

c and the
F1 , F2 with

and

Rbc

to form the faces

(see gure 6.3.8 c)).

The geometry of the folded crease is composed of eight faces. Four faces are triangular
and two are pentagons. A cross section prole with three edges generates six faces, if the
amplitude of the main corrugation is smaller or equal to the maximum amplitude of the
cross section prole (see gures 6.3.10 a) and b)). Furthermore the geometry of the folded
crease is composed of four vertices instead of two.

Indeed at the intersection

ob

of the

side-folds two new reverse folds are generated. The reversed side-folds are oblique to the
projection plane

xz

and therefore the geometry cannot be completely folded.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

151

f2

e2

a)

R ab
f1

F2

ob

rbI

F1

mbc

R ab

A>2r
e1

e2

b)

R ab

rbI

F1
R bc

f2
a

f1

F2

e3

ob

ob
ob

f3

F4
F3

A>2r

e1
R bc

c)

ob

rbI
R ab
f2
f1

F2

e2

F1

R bc

ob
f3

e3

ob
f4

F3

F4

F6

F5
A>2r

e1

F8

e4

F7
y

z
z
y

Figure 6.3.8. Geometry with corrugation amplitude bigger than the max-

imum amplitude of the convex cross section prole:

A > 2rbI

152

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

To analyze the gure we divide it into three parts by parallels to the cross section
prole intersecting the vertices of the reversed side-folds (see gure 6.3.9).
The inner part corresponds to a geometry generated by a convex cross section prole
with three edges and maximum corrugation amplitude (see gure 6.3.9b)). The side-folds
are convex. Note that the cross section prole is not the mid-line of the edges.
The side-folds of the outer parts are convex and concave (see gure 6.3.9c)). They can

kjp. The edges k and n of the zig-zag cross


section prole kjp are parallel to the edges a and b of the convex cross section prole. The
7
inner edge j is k that reects o Rbc . The edges j and p dene a new reection plane Rjp .
I
The order in which the geometries with A > 2r are generated is important. It is
be generated by a zig-zag cross section prole

dierent when they are generated from left to the right than from right to the left (see
gure 6.3.10 , 6.3.11 c) and d)).
When the corrugation amplitude

A > 2rI , convex cross section proles generate geome-

tries with convex and concave side-folds and combine diamond and herringbone pattern.

Convex cross section proles with constant maximum amplitude can generate three dierent type of geometries in function of the corrugation amplitude

(see gure 6.3.10 and

6.3.11):

A < 2rI :

All faces are quadrangles and the vertices have four edges. All side-folds

are convex.

A = 2rI :

The inner faces are triangles, the faces of the rst and the last row are

quadrangles. The vertices have six edges. All side-folds are convex.

A > 2rI :

The faces are pentagons and triangles and the vertices have four edges.

The side-folds are convex and concave (see appendix, gures 11.0.19, 11.0.20).

These three type of geometries correspond to the crease congurations described by

Delarue [Del80, Del94].

The projection of Rjp is the interior bisector of an angle formed by the edge g and the edge hr . The edge
hr is the edge h reected o Rbc .

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

a)
ob

Rab

Rbc

b
j

h
r

R jn

b)
ob

R ab

R bc

b
h

c)

ob

Rbc

b
j
h
k

R jp
p

z
z
y

Figure 6.3.9. Geometry with corrugation amplitude bigger than the max-

imum amplitude of the convex cross section prole:

A > 2rbI .

Decomposi-

tion of the crease in three parts: a) complete geometry, b) and c) decomposed geometry.

153

154

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

a)

b)

c)

z
y
x

developed

Figure 6.3.10. The three types of geometries for a convex cross section

prole in function of the corrugation amplitude


axonometry)

A (developed geometry and

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

e2
f2

R ab

ob
r

I
b

155

a)

e3
f3

Rbc
c

f1

f4
e4

e1

A < 2r Ib

ob (=e2e 3)

b)

rbI

R ab f 2

f3

Rbc

f1
f4
e4

e1

A = 2r bI

ob
R ab

c)

e2

rbI
b

Rbc

f2

f3
a

f1

A > 2r Ib

e3

f4

e4

e1

e2
R ab

ob
rbI
b

Rbc

f3
a

f4

f2

e3

f1

A > 2r bI

z
x

e4

e1

Figure 6.3.11. The three types of geometries for a convex cross section

prole in function of the corrugation amplitude

(frontal view

xz )

156

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.3.2. Zig-zag cross section prole.

If the orientation of a cross section prole

vertices alternates from convex to concave, the cross section prole forms a polygonal zigzag line. Similar to the corrugation prole the general form of a zig-zag cross section prole
is given by a mid-line around which the prole oscillates. It is either straight or curved
and can be chosen arbitrarily. To each cross section prole will correspond a maximum
amplitude of the corrugation prole.

The eective depth of the structure depends not

only on the maximum amplitude of the corrugation prole but also on the depth of the
cross section prole formed by the zig-zag lines. Nevertheless it is important to control the
maximum amplitude of the cross section prole in order to manipulate the pattern and
vertex type.
The zig-zag prole generates concavities in the folded plate geometry. The cross section
prole indicates the slope of each face by the inclination of its edges. This allows control of
the slope of the faces in order to drain the rain water and to avoid concave spaces, where
water can accumulate.
6.3.2.1.
frontal view

Maximum amplitude.
xz .

As for the convex polygonal prole we only consider the

Let a cross section prole be composed of four-edges

determine the external angle bisectors

Rab , Rbc , Rcd

a, b, c

and

and

by the help of the edge extensions (see

gure 6.3.12). Due to the inversion of the vertex orientation, the bisectors are on opposite
sides of the cross section prole. The bisector

Rbc

intersects the edges

and

c
b

a)

b)

R cd
R ab

c
b

R bc

x
y
Figure 6.3.12. Design of a zig-zag cross section prole

d.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

The boundary edges

and

157

of a simply-corrugated surface with an amplitude

run

on both sides of the cross section prole. They are at equal distance and parallel to the
cross section prole and reect o the external angle bisectors (see gure 6.3.13 a). Three
cross section prole edges

a, b

and

dene two external angle bisectors

Rab

and

Rbc .

If

they are not parallel, they intersect each other and form an angle. The boundary edges

e and f of the faces reect o the bisectors within this angle. The edge f2 f3 , parallel to
b, is limited by the angle bisectors. The bigger the amplitude the shorter the edge f2 f3 .
The maximum amplitude Amax is reached when f2 f3 shrinks to a point at the intersection
of the angle bisectors oa (see gure 6.3.13 b)). Beyond that point, the boundary edge
can only reect o one of the exterior angle bisectors.

od

The second bisector intersection

is more distant to the cross section prole. Consequently the boundary edge

is still

composed of four edges.


The cross section prole is the mid-line of two boundary edges and therefore the maximum amplitude

Amax

corresponds to twice the distance between the prole and the angle

bisector intersection. In an arbitrary cross section prole, this distance is dierent for each
triplex of adjoining prole edges. The maximum amplitude

Amax

for an arbitrary prole is

twice the shortest distance between the prole and the exterior angle bisector intersection.

a)

f4
R ab

f2

oa

f3
f1

R cd

e2

e4
R bc

e3

od
d

A
2
A
2

e1

e5

f5

f4
b)

R ab

oa (f2 f3)
a

A
2

R cd

e4
R bc
d

A max

A
2
y

f1

e2

od

e3
A

e5
e1

f5

Figure 6.3.13. Maximum amplitude for zig-zag cross section prole

158

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.3.2.2.

Vertex type and pattern.

The maximum corrugation amplitude changes the

geometry of the adjoining faces and their vertex. Figure 6.3.14 shows regularly corrugated
geometries corresponding to the cross section prole of gure 6.3.13 with main corrugation
amplitudes smaller and equal to the maximum amplitude of the cross section prole.

Normal amplitude: A < Amax

(see 6.3.14a) All faces are quadrangles and the vertices

have four edges. The side-fold rows are alternating from convex to concave and point into
the same direction. They form a typical herringbone pattern.

Maximum amplitude: A = Amax

(see 6.3.14b) The second row of the pattern is com-

posed of triangles instead of quadrangles.

A pair of triangles draw a dart shape.

The

dierently inclined side-folds touch each other at their tip in every second line. They form
a six-edge vertex composed of two convex main-folds and two convex as well as two concave
side-folds.

If for a given zig-zag cross section prole the amplitude of the main corrugation attains
the maximum amplitude of the cross section prole, the valence of the vertices changes
from four to six. Two four-edge vertices collapse and form a six-edge vertex. The middle
segment of the main-fold is reduced to a point which corresponds to the exterior angle
bisector intersection in the frontal view

xz .

Its adjacent faces change from quadrangle to

triangle. Visually the herringbone pattern is more present with a normal amplitude. With
maximum amplitude the zig-zag character of the geometry is less pronounced.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

a)

b)

x
y developed

Figure 6.3.14. Inuence of corrugation amplitude on pattern and vertex

159

160

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.3.2.3.

Ex-circle.

With zig-zag corrugation proles the intersection

is not situated within the triangle formed by the edges

a, b

and

oa

of

Rab

and

Rbc

and we cannot use the

oa is situated outside the triangle close


intersection oa is the center of the ex-circle of the

in-circle to control the amplitude. The intersection


to the edge
triangle

abc.

(see gure 6.3.15 a). The

The ex-circle is tangent to one of the triangle edges and to the extension of

the two other edges (see gure 6.3.15 b). Each triangle has three ex-circles

Ec ,

Ea , Eb

and

tangent to one of the triangle edges. The center of an ex-circle is equidistant to the

three edges

a, b

and

c.

The center of the ex-circle is dened by three angle bisectors: the

interior angle bisector, opposite to the triangle edge which is tangent to the ex-circle, and
8

the exterior angle bisectors adjoining this edge .


In gure 6.3.15 a) the intersection of

Rab

with

Rbc

is the center of the ex-circle

Ea
abc

a . The line Rbc is the interior angle bisector of the triangle


opposite to the edge a. The line Rab is the exterior bisector of the angle enclosed by the
edges a and b. For the triangle bcd, Rbc is again the interior bisector of the triangle, but
this time opposite to the edge d. It intersects with Rcd , the exterior bisector of the angle
enclosed by the edges c and d. The intersection od is the center of the ex-circle Ed tangent
to the edge d.

tangent to the edge

Zig-zag polygonal cross section prole - ex-circle


To each triplex of cross section prole edges corresponds an ex-circle tangent to one of the
edges. We can now dene the maximum amplitude as follows:

E
Amax = 2rmin
where

E
rmin

is the smallest ex-circle radius of the cross section prole.

Vertex conguration and pattern design of zig-zag polygonal cross section prole can be
controlled by the ex-circle radius.

If the radii of all ex-circles are congruent and the

amplitude of the main corrugation corresponds to diameter of the ex-circle, all vertices will
have six-edges and the pattern be composed of triangles. The ex-circle radius is also useful
to guarantee that the maximum amplitude of each cross section prole edge is equal or
bigger than the amplitude of given main corrugation.

Except for an isosceles triangle, the diameter of each of the three ex-circles is dierent.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

a)

R cd
R ab

oa

Ea

Ed

c
b

raE

d
a

R bc

od

rdE

x
y

b)

Ec
1802

oc

c
1802

2
b

Figure 6.3.15. Ex-circle

rcE

161

162

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.3.2.4.

Zig-zag cross section proles with constant amplitude.

Based on the ex-circle

we can design a cross section prole with constant amplitude (see gure 6.3.16).

a and a point oa which is the center of the ex-circle and draw


E
the ex-circle Ea tangent to a. The radius ra corresponds to half the maximum
amplitude Amax of the cross section prole. We design a second edge b tangent
to the ex-circle Ea . The direction of b can be chosen arbitrarily as long as b is
tangent to Ea and not parallel to a.
b) Once the direction of edge b xed, we can draw the exterior angle bisector Rab
of the edges a and b. It is dened by the center of the ex-circle oa and the edge
intersection iab .
c) The third cross section prole edge c is again tangent to Ea . Its direction can be
chosen within an angle dened by the normals of the edges a and b.
d) The exterior angle bisector Rbc is dened by the ex-circle center oa and the edge
intersection ibc . The next ex-circle center o2 is element of the angle bisector Rbc
and at the same distance from ibc as oa .
e The edge d is tangent to the ex-circle Ed . Its direction can be chosen within an
angle dened by the normals of the edges b and c.

6.3.16 a) We dene a rst edge

6.3.16

6.3.16

6.3.16

6.3.16

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

a)

Ea

oa

raE

b
a

b)

Ea

R ab

oa

raE

b
a

c)

Ea

R ab

oa

raE

d)

Ea

R ab

oa

raE

R bc

od

e)

oc

Ea

Rab

oa

Rcd
b

raE

Ed

R bc
od
d

rdE

A max =2r E
y

Figure 6.3.16. Design of a zig-zag cross section prole with constant amplitude

163

164

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

Simplied method

Similar to the convex polygonal pattern, the method to design a

cross section prole with constant amplitude can be simplied (see gure 6.3.17).

The

edges of the cross section prole are reected about a line that originates in the ex-circle
center:
6.3.17 a) We draw a rst cross section prole edge

and dene a point

1
that corresponds to Amax . We reect the edge
2

oa

at a distance to

a about an axis beginning in oa

and whose direction can be chosen arbitrarily under condition that it intersects

a is the second cross section line edge b.


b) The exterior angle bisector Rab of the edges a and b is dened by their intersection
iab and oa .
c) The next edge c is created by a reection of b about a line originating as before
in oa and intersecting b. The direction of the reection line can be chosen within
an angle dened by the angle bisector Rab and the edge b .
d) The exterior angle bisector Rbc of the edges b and c is dened by their intersection
ibc and oa . The second ex-circle center od is part of Rbc and at the same distance
to ibc as oa .
the edge

6.3.17

6.3.17

6.3.17

a.

The reection of

6.3.17 e) By repeating the steps b) and c) we can complete the cross section prole.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

a)
oa
b

b)
i ab

oa

R ab
b

c)
i ab R ab

oa

b
a

d)
i ab R ab
b

oa

c
R bc
i bc

e)
oc

Rcd

i ab R ab

oa

R bc
a

i bc

od
d

A max =2oaa
y
Figure 6.3.17. Simplied design of a zig-zag cross section prole with

constant amplitude

165

166

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

The developed and the folded surface corresponding to the cross section prole of gure
6.3.16 is shown in gure 6.3.18. The faces of the inner rows are triangles and form a dart
pattern. The vertices at the point of the darts have six-edges.
The frontal view

xz

shows the boundary edges. The edges

cross section prole edges

and

f2 f3

and

e3 e4

parallel to the

have shrunken to a point. The outline of the boundary

edges does not show the orientation inversion of the cross section prole.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

167

a)

+
x

y developed

b)

oc (f 4)
o a(f 2 f3 )

f1

e2
R bc

od (e 3e4 )
A max

A max

A
2

e1
A
2

R cd

R ab

e1

f5

x
Figure 6.3.18. Zig-zag folded plate geometry with constant maximum amplitude

168

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.3.2.5.

Ex-circle position in zig-zag cross section proles.

section prole edges

a,b

and

c,

In a series of three cross

the ex-circle is tangent to one of the outer edges (a or

Its position depends on the dierence in value of the bending angles

1 < 2

The ex-circle is tangent to the edge

(see gure 6.3.19 a ).

and

Ea ,

and

, as

c, tangent to Ea , can
Rbc within an angle ,

are set. The direction of the edge

1 and the angle


Rab and b0 parallel to b.

be chosen within an angle


enclosed by the bisector

Suppose we want

to design a prole with constant maximum amplitude and the edges


well as the ex-circle

c)9.

bisector

If we design a cross section prole with more than three edges, the ex-circles
will be alternatively tangent to the rst or to the last of the three edges that

Ea tangent to edge a, the position of


Ed (bcd) , Ec (cde) , Ef (def ) (see gure

dene the triangle. With the rst ex-circle


the ex-circles is the following:
6.3.21). If

Ea (abc)

is convex, the general curvature of the cross section prole will be

convex too and inversely it will be concave if

1 = 2

The edges

Rab

and

Rbc

an

is concave.

are parallel and as a consequence the exterior angle bisectors

are parallel too and do not intersect (see gure 6.3.19 b)).

The

amplitude of the corrugation is not limited and its general extension straight.
This conguration corresponds to the geometry rst described by
and called

1 > 2

Miura Ori.

The ex-circle is tangent to the edge

(see gure 6.3.19 c)).

Miura [Miu70]

Suppose we want

to design cross section prole with constant maximum amplitude, with the edges

and

b,

as well as the ex-circle

Ea

set.

The direction of edge

can be chosen

1 and the angle bisector Rbc within an angle enclosed by


E
Rab and rc perpendicular to b. If we design a cross section prole with more than
within an angle

three edges, the ex-circles will be alternatively tangent to the rst or to the last

Ec tangent to
c the position of the ex-circles is the following: Ec (abc) , Eb (bcd) , Ee (cde)
, Ed (def ) ,Eg (ef g) (see gure 6.3.21). If 1 is convex, the general curvature of
the cross section prole will be concave and inversely it will be convex if 1 is
of the three edges that dene the ex-circle. With the rst ex-circle
edge

concave.

By denition the ex-circle is tangent to the three lines a, b and c, but it only touches one edge of the
triangle and is tangent to the extension of the other edges (see gure 6.3.15)

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

169

Ea
oa

a)

a
b

b'

R ab

b'

R ab
2

R bc

R bc

b)
R ab

R ab

a
b

R bc

R bc

c)
R ab

R ab

a
1

R bc

R bc

r Ec

oc

Ec

x
y

6.3.19
Figure 6.3.19. Ex-circle position

170

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

The folded and the developed geometries corresponding to the cross section proles
of gure 6.3.19 are shown in gure 6.3.20.

The bending angle

is the same for the

three proles and therefore the geometry of the rst side-fold row is identical for the three
patterns.

1 < 2

The convex vertices of the rst and the second side-fold rows coincide.

The

is the following: 1 > 2 > 0. When


angles 1 and 2 is important, the triangular

relationship between the side-fold angles


the dierence between the bending
faces will become very elongated.

1 = 2
1 > 2

The side-fold rows are parallel and the side-fold angle are equal:

1 = 2

The concave vertices of the two side-folded ranges coincide and relationship between the side-fold angles

is inverted :

1 < 2 >

2 . The size of the triangular

faces is limited even when the dierence between the bending angles
becomes important.

and

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

171

1
2

y developed
Figure 6.3.20. Consequences of ex-circle position on folded geometry and

developed pattern

172

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

z
y
x
Ra

oa

Ec

R ab

oc

R bc

R cd
d

R de
e

R ef

od

of

Ef

x
y developed

Figure 6.3.21. Cross section prole with convex curvature:

1 < 2

Ed

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

173

Eg

og

+
R ef

oe

ob

Ee
d

Rde

R bc

Eb

R cd

Rab

R fg

od

Ed

oc
Ec

x
y developed

Figure 6.3.22. Cross section prole with concave curvature:

1 > 2

174

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.3.2.6.
prole

Zig-zag cross section proles with 8 edge vertices.

a, b, c

and

in a single vertex

Four edges of a cross section

d can have three exterior angle bisectors Rab , Rbc and Rcd that intersect
oa : the triangles abc and bcd have a common ex-circle Ea = Eb to which

all edges are tangent. As a consequence, the convex vertices of three side-fold rows coincide
in the folded geometry. The two main-fold edges and the side fold edges form an 8-edge
vertex with one convex and one concave main-fold edge as well as two concave and four

1 < 2 , all
section prole are growing in size: 1 < 2 < 3 . Inversely
of the cross section prole decrease in size: 1 > 2 > 3 .

convex side-fold edges (see gure 6.3.23 and appendix, gure 11.0.15).
bending angles of such a cross
if

1 > 2 ,

all bending angles

If

The number of exterior angle bisectors intersecting in a single vertex could be increased.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

175

a)

+
y developed

oa=ob(f 2 f3 f 4)

R ab

b)

e2
R cd
b

f1
a

A max

Rbc

e4

e3

e5

A max

A
2
A
2

e1

z
x
Figure 6.3.23. Herringbone pattern with 8 edge vertices

f5

176

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.3.2.7.

Plus Ultra: beyond maximum amplitude.

As for convex cross section proles it

is possible to generate geometries where the maximum amplitude of the corrugation prole
exceeds the maximum amplitude of the cross section prole:

E
Amax > 2rmin
Let us consider a zig-zag cross section prole with three edges

and

and the

Rab and Rbc (see gure 6.3.24). A crease with an


E
2ra is reected o the reection plane Rab to form F3 and F4 (see gure

corresponding exterior angle bisectors


amplitude

A>

6.3.24 a) and b)). In the front view

Rbc .

xz ,

the crease edge

f1 f2

intersects the angle bisector

This signies that in 3-dimensional space the side-folds and the faces

intersect the next reection plane

Rbc

(see gure 6.3.24 b)).

F1

F2

and

All four faces are split by

Rbc into eight faces. The poly surface is split in an unusual way. The
faces F3 , F4 , F5 and F6 in the middle of the poly-surface are above the reection plane and
the F1 , F2 , F7 and F8 are below the reection plane Rbc (see gure 6.3.24 b)). Normally a

the reection plane

reection plane splits a crease in two parts, where one end of the poly-surface is below, and
the other end above the reection plane. In order to constitute a continuous poly-surface,
the faces on both ends,
plane

Rbc .

F1,

and

The rst two faces

F2 ,

F1

as well as

and

F2

F7

and

F8 ,

have to be reected about the

do not correspond anymore to the edge

of the

cross section prole. In order to nd a correspondence between the cross section prole
and the folded surface, the edge
new cross section prole

ar abc

has to be reected about the angle bisector

has four edges which reect twice o

Rbc .

Rbc .

This

The so folded

crease is composed of six side-folds instead of four. The reections about the plane
generate two additional side-folds
the side folds
and

s2

s1

and

s2

s5

and

ss .

Furthermore the reection about

s1 , s2

splits

in two parts. Like a main fold, one part of the convex side folds

is reversed and becomes concave. The additional side folds

of the side folds

Rbc

Rbc

s5 , s6

s1

and the reversion

generate three additional vertices. The folded crease has ve inner

vertices. The poly-surface of the folded crease is composed of eight faces. Four faces are
triangular and four are pentagons.

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

177

e2

a)
f2

F1
F2

oa

R ab

raE

e1

R bc

A>2raE

R ab

f1

b)

f2

E
a

oa r

R ab
e2

e1

F1

F2

oa

s2

oa

s1

R bc

f1

A>2raE

f3

R bc

F4

F3
e3

F2

c)

s1(+)
e3

A>2raE

e1
Rab

e2

f3

oa
raE
a

f2

f4

oa

s5 s6

s1(-)
s3

f1
ar

oa

F1

f5

s1(+)
s1(-)
s4
F4
F6

F3
F5

R bc

F7

Figure 6.3.24. Geometry with corrugation amplitude bigger than the

maximum amplitude of the zig-zag cross section prole :

A > 2rb

F8

178

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

To analyze the gure we split it into three parts by parallels to the cross section prole
intersecting the side-folds intersections (see gure 6.3.25 a)). The inner part corresponds
to a geometry generated by a zig-zag cross section prole with four edges and maximum
corrugation amplitude (see gure 6.3.25 b)). The side-folds are convex and concave. The
geometry is similar to geometry generated with a cross section prole with eight-edge
vertices described in section 6.3.2.6.
The exterior parts can be generated by a convex cross section prole with two edges

k.

and

The edge

r
is parallel to a , the reection of

about

Rbc ,

and

parallel to

c.

The

side-folds of the outer sections are concave.


The situation of convex cross section prole with corrugation amplitude
(see section

A > 2rI

6.3.1.5) is inverted: the inner part of the gure can be generated with a zig-

zag cross section prole and the exterior parts with convex cross section proles. Although
this geometry is theoretically possible, it is dicult to control it in practice.

Indeed,

when the number of edges of the cross section prole is increased, the number of sidefolds intersecting multiple reection planes increases and the geometry becomes dicult
to control.
The order in which the geometry is generated is important. It is dierent when generated from the left to the right, than from the right to the left (see gures 6.3.26 c) and
6.3.27 c)).

Zig-zag cross section proles with constant maximum amplitude can generate three dierent type of geometries in function of the corrugation amplitude

(see gures 6.3.26 and

6.3.27):

A < 2rE

All faces are quadrangles and the vertices have four-edges.

All side-folds are

convex and concave.

A=

2rE The inner faces are triangles, the faces of the rst and the last row are quadran-

A>

2rE The faces are pentagons and triangles and the vertices have four-edges.

gles. The vertices have six edges. The side-folds are convex and concave.
The

side-folds are convex and concave.

These three types of geometries correspond to the crease congurations described by

Delarue [Del80, Del94].

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

a)

A>2raE

R hrg

hr

Rab
h
z

ar

g c

oa

R bc

b)

hr
Rab
h

ar

g c

oa

R bc

c)

R hrg

hr

j
h

oa

R bc

z
y

Figure 6.3.25. Geometry with corrugation amplitude bigger than the

maximum amplitude of the zig-zag cross section prole :

A > 2raE .

De-

composition of the crease in three parts: a) complete geometry, b) and c)


decomposed geometry.

179

180

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

a)

b)

c)

z
x

Figure 6.3.26. Geometry with corrugation amplitude greater than the

maximum amplitude of the zig-zag cross section prole :


oped pattern and axonometry

A > 2rE .

Devel-

6.3. LIMIT CONDITIONS OF CROSS SECTION AND CORRUGATION PROFILE

181

e4

a)

f4
c
R ab

f2

oa e2
raE

e3 b

f3

e1
A<2raE

R bc

f1
e4

b)
f4
c
R ab

f2

oa(=e2,e3 )
b

raE
e1

f3

A=2raE

R bc

f1

e3
A>2raE

f1

c)

e1
e2

R ab

f3

oa
raE

f5

f2

f4

R bc

e2
oa

R ab
f3

raE

f2

e1

e4
b

e3

R bc

A>2raE
z

f1

e5

x
Figure 6.3.27. Geometry with corrugation amplitude greater than the

maximum amplitude of the zig-zag cross section prole :


Frontal view

xz

A > 2rE .

182

6. GEOMETRIES BASED ON REVERSE FOLD IN ORTHOGONAL PROJECTION

6.4. Discussion
The cross section prole is an interesting tool to design and control the general shape
of a folded plate geometry. It directly draws the section of a space. Functional and spatial
parameters can be integrated into the design.
Structural considerations can be taken into account by the shape of the prole, favoring
a direct load transmission to the ground, but also by the control of the corrugation amplitude. It is possible to design cross section proles which guarantee a desired corrugation
amplitude in all points and thus control the structural depth (see appendix, gure 11.0.2).
The structural strength will not only depend on the corrugation amplitude but also on the
inclination of the corrugation edges (see appendix, gure 11.0.8).
The transverse inclination of the faces, composing the folded plate geometry, can also be
controlled by the cross section prole. This guarantees that rain water is always naturally
drained to the ground.
The general shape is limited to cylinder surfaces. For cross section proles with big
maximum amplitude the cylinder shape can be modied by the geometry of the corrugation prole. In such geometries the corrugation mid-line is like a corrugation at a bigger
scale: big folds, modifying the general shape, are superposed on small folds, corrugating
the surface.

This is adapted to simple cross section proles with few edges, where the

undulation of the general form can have a real visual and spatial impact.

Nevertheless

the geometries stay restricted to cylinder surfaces that oscillate more or less close to the
reference surface. This restriction is due to two factors:

Vertex geometry

The geometries are based on simply-corrugated surfaces with straight

main-folds, which means that the vertices are always composed of two edges that form
a continuous, main-fold and two oblique side-folds. A more general model presented by

Tac09] is able to take into consideration four-edges vertices with arbitrary congu-

Tachi [

rations. This allows double-curved surfaces. Their form generation is more complex than
the method we propose and they do not have the advantage of being cut out of parallel
strips.

Single patch geometry


continuous faces.

The proposed geometries can be developed to a surface with

As soon as we allow the surface to be non-continuous, doubly-curved

surfaces, composed of multiple patches, can be modeled (see appendix, gures 11.0.21,
11.0.22). Particularly rotational surfaces, which are close to the shapes that can be obtained by deforming paper models, can be generated (see appendix, gures 11.0.23, 11.0.24,
11.0.25). Doubly-curved diamond surfaces can also be designed by a method proposed by

Thonon [Ton93].

Future work may show how to simplify its method in order to integrate

it into our model.


The vertex conguration and the patterns type of the developed surface can also be
controlled by the cross section prole. It is the vertex orientation of the cross section prole
that determines the side-fold orientation and thus the shape of the faces composing the
surface. There are two main patterns:

Hexagonal Pattern

It is based on a convex polygonal cross section prole.

6.4. DISCUSSION

Herringbone Pattern

183

It is based on zig-zag cross section proles.

Combinations of convex and concave folds can be used to create various other patterns.
To each cross section prole corresponds a maximum amplitude which sets the maximum amplitude of the corrugation prole. The maximum amplitude can be controlled by
the in-circle, for convex polygonal cross section proles, and by the ex-circle, for zig-zag
cross section proles.

Pattern and vertices of cross section proles with constant maxi-

mum amplitude change: two adjoining vertices collapse and form a six-edge vertex and
the quadrangular faces of the pattern become triangular. The control of the amplitude is
important to guarantee a structural depth, and to control the pattern type. Furthermore
it is important to ensure a given amplitude of the cross section prole when the shape of
the corrugation prole is irregular, for example, if its mid-line is curved or polygonal. In
this case the pattern type is not, or only locally, modied (see chapter 9, gure 9.2.2).
The control of convex polygonal cross section proles with constant maximum amplitude is not much constraint: there is lots of freedom to choose the direction of the prole
edges and the form of the cross section prole is close to the shape of the folded plate
geometry.
The control of zig-zag cross section proles with constant amplitude is more delicate.
The fact that two ex-circles can be chosen as reference for a new edge, and that its direction
is more limited, makes the control of the general shape dicult. With constant maximum
amplitude the zig-zag shape of the main-fold disappears and the side-folds characterize
the general form. Therefore, the cross section prole, even though it generates the form,
is not always directly representing the general shape.

The faces of such geometries are

triangles with acute angles. For timber construction these angles might be problematic for
assembling, handling and transport.

CHAPTER 7

Oset
7.1. Introduction
To build the generated polygonal surfaces with timber panels we have to give a thickness
to the surface.

Generally we want to build folded plates structure with panels of equal

thickness and therefore create an oset of all the faces at equal distance (see gure 7.1.1).
In polygonal surfaces, the face edges meet in a vertex.

If we oset the surface, the

edges of the oset faces should ideally meet in a single vertex again. This only happens
under certain conditions depending on the geometry and the topology of the vertex. In the
folded plate geometries that we are interested in, mainly two vertex types appear: the most
common, the four-edge vertex, directly stems from the reverse fold. When the corrugation
amplitude corresponds to the maximal amplitude of the cross section prole two four-edge
vertices collapse and form a six-edge vertex.
First oset in both types of vertices were investigated. We found that six-edge vertices
cannot be oset with all the edges intersecting in one vertex.

With four-edge vertices,

the oset of the faces with edges intersecting in a single vertex is possible under certain
conditions. It is interesting to note that these conditions depend on whether the geometry
is completely foldable or not. If the inclination angles of the faces are symmetric, which
means the geometry is completely foldable, the oset in a single vertex is possible. In the
following, we will describe the oset conditions of both, four-edge and six-edge vertices
in symmetric and asymmetric position and some consequences for the generation of the
geometry for folded plate structures.

Figure 7.1.1. The geometry gets physical


185

186

7. OFFSET

7.2. Four-edge vertex oset


7.2.1. Oset.
d.

An oset surface is a surface parallel to the original surface at a distance

The distance is measured on the normal to both surfaces. In a poly-surface, all faces

are oset with the same distance, normal to the original faces.
Let us consider two faces
normals to the faces
a plane

n1

and

F1 and F2
n2 indicate

with a common edge

e12

(see gure 7.2.1). The

the dihedral angle between the faces and dene

perpendicular to the faces. The edge

e12 ,

common to both faces, is normal to

F1 and F2 are at equal distance d to the original faces. Therefore,


0
their intersection e12 is an element of the bisector plane B . The edge e12 and the interior

P.

The oset faces

bisector

b12

of the angle enclosed by the normals

which is perpendicular to

P.

n1

and

The interior angle bisector

n2 ,

b12

dene the bisector plane

and the edge

e12

form a right

angle.
In reverse folds, four faces form a four-edge vertex. The oset faces intersect in a single
vertex under condition that the bisector planes of all faces intersect in a single edge.

7.2. FOUR-EDGE VERTEX OFFSET

187

B
P
e'12

F'1
e12
n1

b12

F'2
n2

F1

F2
z

y
x
B

e'12

F'1
n1

b12

F'2
n2

e12
d

F1

F2

x
Figure 7.2.1. Oset for two faces

188

7. OFFSET

7.2.2. Symmetric reverse fold.


faces

F1

F2

F3

and

F4

Let us consider a symmetric reverse fold with four

and the corresponding normals to the faces

n1

n2

n3

and

n4

(see gure 7.2.2). We position the origin of all normals on the vertex such as they indicate
the dihedral angle between the four faces and dene the interior angle bisectors

b23

and

b14 .

The faces

e24 .

b12 , b34 ,

F3

and

F4

have been reected about a plane

Therefore, their normals

n1

and

n3 ,

respectively

n2

and

R dened by edges e13 and


n4 , are symmetric about the

R, nR (see gure 7.2.3). The normal nR is the interior angle bisector of the
angles n1 n3 and n2 n4 and the intersection of the bisector planes B13 and B24 .
The bisector planes B12 and B34 have to intersect in nR too, so that all bisector planes
intersect in a single edge. The normal nR is also the interior bisector of the angle enclosed
by the main-fold edges e12 and e34 (see section 5.5.2.3). In order to intersect with the
normal nR the bisector planes B12 and B34 have to form a single plane, congruent with
the crease edge plane M , dened by the main-fold edges e12 and e34 . This is the case when
the faces F1 and F2 , respectively F3 and F4 , are symmetric to the crease edge plane M

normal to

(see gure 7.2.4).

The symmetric reverse fold can be oset. It fullls the conditions for an oset formulated
by

Pottmann [PLW+ 07].

In a four-edge vertex the sum of the opposite angles has to be

equal so that the oset faces meet in a single vertex:

2 + 1 = 1 + 2

n2
e 13

n1
F1

n2

F2
F3

F1

e 12
F2

b12

n3
1

F3

e 24
n1

F4
2

F4

n3

nR = b13 = b24
e 34

n4
b34

n4
y

Figure 7.2.2. Normals and dihedral angles of a reverse fold

7.2. FOUR-EDGE VERTEX OFFSET

nR = b13 = b 24
n1 n2

189

n3 n4
F1 F2

F3 F4

Figure 7.2.3. The normal to the reection plane

bisector planes

B13

and

nr

is intersection of the

B24

F'1
F'2

B12

B13

nR

B23

B34

F'3
F'4
y

Figure 7.2.4. Bisector planes and oset faces

190

7. OFFSET

7.2.3. Asymmetric reverse fold.


M,

In asymmetric reverse folds the crease edge plane

e12

containing the main-crease edges

and

e34

and the normal

nr

of the refection plane

is not congruent with the bisector planes. The sums of the opposite angles are not equal,

1 and 2

since the side-fold angles

have dierent sizes.

Therefore an oset in a single

vertex is not possible. Due to the asymmetry, the bisector planes


with regard to the crease edge plane
bisector planes oscillate about

e034

and

M.

B12

and

B34

are rotated

(see gure 7.2.5). Since the fold is reversed the

This results in a shift of the oset main-fold edges

e012

which do not intersect anymore.

Nevertheless, the bisectors planes

B12

and

B13 ,

as well as

B24

and

B34 ,

do intersect.

There is a triangular gap between the two intersections that indicates the shift of the oset
main crease edges

F20 and

e012

and

e034 .

The oset faces

F10

and

F40

stay quadrangular. The faces

F30 have ve edges.

For osets of asymmetric reverse folds, the main-fold edges are shifted and the resulting
poly-surface has two inner vertices. This happens independently to the side on which the
surface is oset (see gure 7.2.7).

e'12
F1

n1

B34

e12

F2

B12

F1

n2
e'34

e'12
e

F3

B12

F3

F2

F4
e34

F4

n4

nR

B34

n3

a)

b)

e'34

Figure 7.2.5. Bisector planes with asymmetric reverse fold

z x
y

F2

7.2. FOUR-EDGE VERTEX OFFSET

191

F'1
F1

F2

B12
B13

B24

F'2

e'12

e'13

F4

e'24

F3
B34
F'3

F'4
e'34
y

b)

a)

z x

Figure 7.2.6. Bisector planes and oset faces of asymmetric reverse fold

B12
F1
F2
B13

B24

B34
F3

F4

Figure 7.2.7. Bisector planes and oset faces of asymmetric reverse fold

192

7. OFFSET

7.3. Six-edge vertex oset


Six-edge vertices can be considered as two collapsed four-edge vertices. The main-fold
edge between the two vertices is reduced to a point. There are two congurations:

In convex polygonal cross section proles, the side-fold arrows are opposite. The
side folds form an x crossed by the straight main-fold.

In zig-zag cross section proles the side-fold arrows have the same direction. The
side folds form a double arrow crossed by the straight main-fold.

It has been shown that the only possible intersection of the bisector planes of a four-edge
vertex is the normal to the reection plane. If two reection planes intersect, as happens
in the case of six edge vertices, they do not have a common normal. Therefore, six-edge
vertices cannot be oset such as the oset faces intersect in single vertex.

7.3.1. Symmetric six-edge vertices.

Each single four-edge vertex, composing the

six-edge vertex, can be oset if it is symmetric. We show the consequences on the oset
surface, if the two vertices collapse, for the two vertex congurations:
7.3.1.1.

nR1

and

Convex polygonal cross section prole.

nR2

The normals to the reection planes

form an angle intersecting at the vertex.

The consequences are dierent

whether the surface is oset to the convex or to the concave side.

Convex side

(see gure 7.3.1 a)) The angle between the normals is opening and the two

oset vertices move away from each other. The middle main edge segment

e34 ,

that disappeared in the original surface, reappears in the oset surface forming a
hexagonal pattern. The oset surface looks like a folded surface with two reverse
folds that have non-maximal amplitude.

Concave side

(see gure 7.3.1 b)) The normals intersect each other and the oset vertices

of each reverse fold penetrate into the opposite oset surface. Therefore, the sidefold edges
plane

M.

e13

and

e35

as well as

e24

and

The oset faces are truncated.

e46

intersect outside the main crease

7.3. SIX-EDGE VERTEX OFFSET

nR2

193

nR1

nR1

nR2

e'56

e'12
e56

e56

e12

e12
e'56

F'1

e'12

F'2

e'12
F'2

F'1
e'12
F'3

e'34

e'13
F'4

F'3

e'24
F'4

e'35
e'56

e'46

F'6

F'5

e'56

F'5
F'6
a)

b)

Figure 7.3.1. Six-edge vertex with convex polygonal cross section prole

and symmetric corrugation

194

7. OFFSET

7.3.1.2.

zig-zag cross section prole.

The consequences are the same as for the convex

polygonal prole: if the surface is oset to the convex side, the middle segment of the
main-fold edge reappears forming a herringbone pattern.

The surface looks like if the

corrugation amplitude would not be maximal (see gure 7.3.2 a)). If the surface is oset
to the concave side, the vertices of the side-folds intersect and the oset faces are truncated
(see gure 7.3.2 b)).

nR1

nR2

nR1

nR2

e'12

e12

e12

e'56

e56

e'12

e56
e'56
F'1
e'12

F'2

e'34

e'12

F'3

F'1

F'4

F'2

F'3

e'56

F'4
e'56

F'5
F'6

F'5

y
a)

F'6
zy

z x
b)

Figure 7.3.2. Six edge vertex with zig-zag cross section prole and sym-

metric corrugation

7.3. SIX-EDGE VERTEX OFFSET

7.3.2. Asymmetric six-edge vertices.

195

With asymmetric corrugations the phenom-

ena described in 7.2.3 and 7.3.1 overlay:

Convex

(see gure 7.3.3 a) and 7.3.4 a)) For osets to the convex side the oset vertices
move away from each other and the reappearing edge of the main-fold is shifted
relative to the crease edge plane

M.

The form of face

F40

becomes hexagonal and

the oset face loses its initial character.

Concave

(see gure 7.3.3 b) and 7.3.4 b)) The osets to the concave side have a similar
conguration as symmetric six-edge vertices, except that the side-folds do intersect
in asymmetric positions to the main-fold edge. In the case of zig-zag cross section
prole we observed strong dierences in the oset conguration depending on the
bending angles.

nR2

nR1

nR2

e'56

nR1

e'12
e56

e56

e12

e'56

F'1

a)

e12
e'12

b)
e'12

F'2

F'3

F'1

F'2

e'12

e'34
F'4

F'3

F'4

e'56

e'56

F'6

F'5
F'6

F'5

z
x

Figure 7.3.3. Six-edge vertex with convex polygonal cross section prole

and asymmetric corrugation

196

7. OFFSET

nR2

nR1
nR2

e'12

nR1
e12

e12

e'56

e56

e'12

e56
e'56

e'12

F'1

F'2

e'34
F'3

F'2

F'1
e'12

F'4

F'4
F'3

e'56

e'56

F'5
F'6
z

F'6
F'5

y
x

a)

b)

Figure 7.3.4. Six-edge vertex with zigzag cross section prole and asym-

metric corrugation

7.4. DISCUSSION

197

7.4. Discussion
The oset of four-edge vertices is only possible for symmetric folds. With asymmetric
folds the oset main-fold edge is shifted realtive to the crease edge plane
fold.

The faces of the oset surface do not meet in a single vertex.

at each reverse

The distance of

shifting depends on the degree of asymmetry and on the oset distance. It has important
consequences for the conception of folded plate geometries.
When the vertex conguration inside and outside of a folded plate structure has to
be identical, the edges of the corrugation prole must have constant inclination angles.
This means that only completely foldable geometries can be oset such as the vertex
conguration is the same on both sides. Furthermore, only parallel corrugations can be
used. Oblique folds are asymmetric and cannot be oset in a single vertex. This is also
a strong constraint from an engineering point of view: it does not allow one to incline
some faces more strongly in order to strengthen the structure. Nevertheless, we can still
increase the amplitude of some folds. From a construction point of view this restriction
might be a simplication: the bisector planes of all main-fold edges have the same angle
which facilitates the assembling and simplies the connections between main-folds (see
chapter 9, gure 9.3.1 f ) and 9.4.2)).
In case of asymmetric folds, a decision has to be made whether the single vertices
are outside or inside of the initial poly-surface.

If the single vertices are outside, the

exact composition of the construction has to be known in order to dene the denitive
geometry of the structure. When the structure can be visible inside, which is one of the
big advantages of folded plate timber structures, we suggest to have the original geometries
inside and to oset to the outside.

With small asymmetries or thin osets, the shift of

the main-fold edge might be very small so that it may not be considered by the carpenter.
This could lead to problems of tolerances during the assembling. The shift of the main-fold
edge can also be considered as a positive element and give a special tectonic to a folded
plate structure (see appendix gure 11.0.26).
If the maximum amplitude of the cross section prole is constant and correponds
to the amplitude of the main corrugation, only regular corrugation proles with constant
inclination angles

are reasonable.

In those cases the oset to the convex side is preferred .

The oset surface restores a geometry with non-maximal amplitude whereas the oset to
the concave side introduces a new tectonic which is not in the nature of the original surface.
With irregular inclination angles

, the vertex conguration of the oset surface denatures

the sharpness of the original geometry. The geometry of the oset faces becomes complex
and seems more dicult to build.
An alternative for the oset vertex conguration might be the method proposed by

Stotz [Sto09].

He cuts the edges of all faces such as on the original side they meet in a

single vertex and on the oset side they form a negative pyramid.
1

This is only possible for convex polygonal cross section proles since zig-zag cross section proles are
convex and concave by denition.

198

7. OFFSET

It is important to be aware of the inuence of the inclination angle

and the vertex

conguration on the oset surface right from the beginning of the design process (see
chapter 9).

Part 3

Prototypes

CHAPTER 8

Plywood Prototype 01
8.1. Introduction
The construction of a rst prototype (see gure 8.1.1) was eected quite early in the
thesis study and had three goals:

First

To represent a folded plate structure on 3D modeling software (Rhinoceros) and


to examine its accurateness with a physical model. At that time the method
of generating folded plate geometries with a corrugation and a cross section
prole was not yet established.

Secondly

To compare the deformation and the load capacity of the prototype with modeling of three dierent Finite Element Programs.

Thirdly

To collect rst experiences with the connections of plates and the assembling
process.

Figure 8.1.1. Plywood prototype 01


201

202

8. PLYWOOD PROTOTYPE 01

8.2. Geometry
The geometry of the folded plate structure is dened by a regular corrugation prole
with the following parameters (see gure 8.2.1):

= 30
Amplitude A = 138.6 mm
Interval I = 240 mm
Width W = 277 mm
Total Interval Itot = 2880 mm
Inclination angle

The cross section prole describes a segment of a circle and has the following parameters
(see gure 8.2.1):

r = 3351 mm
span: s = 6462 mm
clearance height: h = 2362.7 mm
bending angle: = 135
edge length: e = 749.6 mm for the
radius of circle:

inner edges and

e = 586.9 mm

for the border

edges
At the time we did not have a CNC milling machine at our disposal and the faces had to
be cut by hand. Therefore the geometry is composed of a single face and its symmetrical
part. The only exception are the faces touching the ground which are cut horizontally in
order to form a linear support. In total, the folded plate geometry is composed of 144 faces
that form 12 arcs with 12 faces. The basic form is a trapezoid with two parallel sides of

960 mm respectively 530 mm of length and a width of 277 mm. The acute, opposite angles
of the triangle have 20 and 40 degree respectively.
The thickness of the panels is 21 mm : they are designed with a miter cut. Due to the
constant inclination angle of the corrugation edges the oset did not cause problems.

8.3. Model
The correctness of the geometry and its oset where tested in a reduced scale (see
gure 8.3.1). The model, composed of 6 arches with 12 panels and an approximate span
of

2000 mm,

showed good correspondence with the virtual geometry.

The panels were

connected by screws and there were few imprecisions due to milling. The structure could
easily support the author's weight.
In a second step, 6 elements where fabricated and assembled at full scale. Again the
precision was satisfying but it showed the necessity of falsework for the assembling of the
nal structure.

8.4. Joints
The panels were assembled by self drilling screws ( 5 mm,
every

50 mm in staggered rows in the mid-plane of the panels.

l = 80mm

) , arranged

Even though this joint does

not correspond to the norms (the screws are parallel to the bers and the distance to the
edge of the panel is too short) it seemed well adapted because the assembling was very

8.4. JOINTS

203

y
x

=2

77

.1

A=138.6

=30.0

I=240.0
e=749.6

=135

h=2362.7

e=586.9
r=3351.0

s=6462.0

z
x

140

20

160

40

277

534

y
x developed

965

Figure 8.2.1. geometry of the prototype

204

8. PLYWOOD PROTOTYPE 01

easy and the panels do not split because the screws are self drilling. The bending stiness
of this connection was evaluated in a series of four preliminary tests. This was necessary
to determine the spring resistance of the joint that could then be used in the structural
modeling. Therefore two panels were assembled in a V-shape and put under vertical load.
The relation between the vertical deformation and the load allowed us to dene the spring
resistance

(see gure 8.4.1).

8.5. Fabrication and erection


The trapezoids can be arranged for the milling so that they can be milled with a few
cuts and a minimum of waste (see gure 8.5.1 a)).

The skew miter cut automatically

produces the mirrored counterpart. Templates have been used for the accurateness of the
milling. Nevertheless small errors and imprecisions appeared.
1

mm
( K,ser = 3.953 106 Nrad
)

Figure 8.3.1. a) Model of the prototype b) four elements form a reverse fold

a)

c)

b)

screw 5,0 / 80

screws in staggered rows every 50mm

Figure 8.4.1. preliminary test of the joint

8.5. FABRICATION AND ERECTION

205

For the assembling, two symmetrical trapezoids are connected along their parallel sides
to V-shapes with the help of falsework (see gure 8.5.2 a).

Two trapezoids assembled

along their long side form a piece with an acute vertex and an obtuse dovetail, inversely,
assembled along their short side, they have an obtuse vertex and an acute dovetail (see
gure 8.5.1 b) and c)).

These two basic elements are again assembled with the help of

falsework to a piece that forms a reverse fold with four faces (see gure 8.5.2 b) and
8.3.1 b)). In the next step, six reverse folds are assembled lying horizontally on their side
to a complete arc of the structure. The following two arcs were assembled on top of the
rst. These three arcs, which make half of the structure, were erected and connected with
their counterpart to form the complete barrel vault.
Elements of uncertainty during the construction of the prototype were the precision of
the the milling and of the assembling. It has been shown that the panels were suciently
precise and that the V-shape and reverse fold elements were exible enough to tolerate small
errors. The fact that individual elements are relatively exible, and that the stiness of the
structure increases with the number of assembled elements, is an advantage of folded plate
structures.

It allows fabrication of panels with high precision and creates the necessary

Figure 8.5.1. Trapezoids: arrangement for the milling, symmetric panels,

assembled V-shapes

Figure 8.5.2. Connection of the panels with the help of falsework

206

8. PLYWOOD PROTOTYPE 01

tolerances for the assembling, with the exibility of the individual elements. This has to
be veried on larger scale structures.

8.6. Loading tests


The deformations of the prototype have been measured by a series of load tests with

PW06, NPW06].

small loads [

The loads have been introduced in three zones (see gure

8.6.1)
(1) Symmetrical load in the center of the arc on 4 side-folds (charge Fates):

41, 0 kN

(2) Asymmetrical load on the north side of the arc on 2 main-folds (charge Nord):

2 2.2 kN
(3) Asymmetrical load on the south side of the arc on 3 main-folds (charge Sud) :

3 2.2 kN
A series of sensors measured the vertical displacement of the structure during the load
tests (see gure 8.6.1).
At the end of the deformation tests we increased the loads until rupture of the structure.
The loads were introduced simultaneously on the north and the south sides. Even though
positions of the load introduction are symmetric they oer dierent support conditions.
In fact convex and concave folds invert in the center of the barrel vault, so that the load
in the north can be introduced on two main-folds and in the south on three main-folds,
which leads to an asymmetric load introduction. The rupture started with a load of

27 kN

when the concave main-folds in the center, close to the southern load introduction, began
to rip open (see gure 8.6.1 and 8.6.2 a)). As was the load introduction, the deformation
was asymmetric: in the second phase of rupture, the barrel vault was strongly pushed to
the south side and the convex main-folds near the support ripped open (see gure 8.6.1
and 8.6.2 b)). The failure of the structure was clearly due to an insucient distance of the
screws to the edge of the panels (see gure 8.6.3)

Figure 8.5.3. Assembling of reverse folds to the barrel vault

8.7. STRUCTURAL DESIGN

207

8.7. Structural design


Parallel to the construction of the folded plate structure its resistance has been calcu-

Charge Nord

load introduction

Charge Fates

sensor

failure zone a

failure zone b

Charge Sud

lated on three dierent Finite Element FE software applications (SAP, RFEM, ANSYS).

convex fold
concave fold

Figure 8.6.1. Load introduction points, situation of the sensors and fail-

ure zones

Figure 8.6.2. The main-folds rip open

208

8. PLYWOOD PROTOTYPE 01

The simulations were realized by engineers of the IBOIS [

PW06, NPW06] .

Four dier-

ent loadings, corresponding to the three loadings of the prototype and to its dead weight,
have been calculated. The comparison of the results shows big dierences between the software applications (see table 1). One element that strongly inuences the outcome is the
rotation freedom of the joints. When the rotations are blocked two software applications
show similar results (see table 1 lower lines). When the joints are modeled as hinges with
free rotations, the results strongly dier (see table 1 upper lines). The planned folded plate
structures can hardly be realized with rotational sti joints. A certain rotational freedom
always has to be allowed and ideally the joints are free for rotations which simplies the
connection between two panels.
An other element that inuences the simulation is the mesh size used in the FE software.

Preliminary calculations on single plates showed that, due to the acute angles of

the plates, a strongly rened mesh with smalls elements has to be used. This slows down
the calculation and might also inuence the result in the sense that it stiens the overall
structure.
The comparison between the deformations of the prototype and the calculations, which
considered the relative bending stiness of the joints evaluated in the preliminary tests,
showed that the prototype is much more exible than the predictions of the calculations
indicate (see table 2) .

Figure 8.6.3. Failure of the connection

8.8. DISCUSSION

209

8.8. Discussion
The construction of the prototype showed the feasibility of folded plate structures based
on origami geometries. In regard to the complexity of the structure, the fabrication and
the assembly did not cause particular problems. The exibility of the elements seems to
be able to absorb small variations in fabrication and assembly.
The failure mode of the structure showed:

The joints between the panels have to be improved.


It is probable that with better joints the rupture load could have been increased.

The comparison of the dierent calculation software applications showed that further research needs to be done in order understand and correctly simulate the structural behavior
of folded plate structures.
The fact that the prototype is much more exible than the results of the calculations,
indicates that the joints have to be considered as hinges with rotational freedom.

This

would also be an economic advantage because such connections are easier to realize.

HW07,

These results engaged new engineering research for folded plate structures [

HW08b, HW08a, Hah09].

Table 1. Comparison of the of the results of dierent FE software, upper

line: free rotations, lower line blocked rotations

Table 2. Comparison of the real and the calculated deformations

CHAPTER 9

Plywood Prototype 02
9.1. Introduction
The second prototype was designed for an exhibition. Its goal was to illustrate the possibilities of shaping forms with the origami-based form generation method. The intention
was to show a geometry whose general form varies and oers dierent perceptions when
turning around the object. Furthermore the suitability of such geometries for integrated
manufacturing should be demonstrated by applying the tools developed by

Sto09].

thesis work [

Figure 9.1.1. Spiral paper folding


211

Ivo Stotz

in his

212

9. PLYWOOD PROTOTYPE 02

9.2. Geometry
The form is a vertical, polygonal cylinder whose shape varies from the ground to the
top. The cylinder is not closed, so that the visitor can perceive the inside of the object.
The form is inspired by a regularly curved paper folding put on its small side and which,
due to the suppleness of the paper, describes a spiral (see gure 9.1.1). It plays with the
ambiguity of the inside outside perception inherent to folded geometries: a convex fold seen
from outside becomes concave inside. Every fold is simultaneously inside and outside, and
reverses from concave to convex when changing direction. This perception is accentuated
by the spiral form and gives the geometry the quality of an innite surface that returns on
itself, similar to a Mbius strip.
In order to vary the general shape, the corrugation mid-line is slightly curved. This
squeezes the faces alternatively inside and outside (see gure 9.2.1).
oset equidistant to each side, which keeps the amplitude constant.

The mid-line was


In a next step the

corrugation prole was drawn within the two oset curves. Because the object was visible
from inside and outside, we wanted to have the same vertex type on each side. Therefore
the inclination angles

of the corrugation edges are congruent, and the main-folds of the

simply-corrugated surface are parallel (see gure 9.2.2). In combination with the constant
amplitude

this signies that the interval

and the width

vary. The fact of choosing

a constant inclination angle has an other advantage: all bisector planes are parallel, in this
case parallel to the ground, which facilitates the mounting and assembling of the structure.
Every row of faces can be assembled independently on a horizontal surface and then piled
up. The maximal amplitude of the corrugation prole is the horizontal distance between
the outermost vertex

and the innermost vertex

f.

The cross section prole is a six-edge polygonal line. The maximal possible amplitude
varies for each edge. The cross section prole was designed so that the amplitude of each
edge (A2 ,

A3 , A 4 , A 5 )

is bigger than the maximal corrugation prole amplitude

Amax .

This guarantees that all faces are quadrangular and all vertices have four edges (see gure
9.2.2).

Figure 9.2.1. General shape and corrugated shape of the prototype

9.2. GEOMETRY

213

A
I12

I11

i4
I10

A4

I9
R 34

R 45

I8
e4

i3

I7

A3

e3

e5

I6

i5

e6

I5

R 23

R 56
e2

I4
I3

A5

f'
e1

A2

i2
x

A max
g'

R 12

I2
I1

= 60

A max
W12

W11
W10

W9
W8
W7
W6
W5
W4
W3
z

+
x developed

W2
W1
1

Figure 9.2.2. Corrugation and cross section prole of the prototype

214

9. PLYWOOD PROTOTYPE 02

9.3. Fabrication and erection


As for the rst prototype we decided to use
available in a size of

Oset

2500 1250 mm

21 mm

thick plywood panels that are

. The fabrication consisted in the following steps:

Starting from the poly-surface the faces have been oset automatically by the
help of a script. For general planar, quadrangular meshes, the oset in a single
vertex is not possible. In this case the corners of the panels are cut by a triangular

Sto09].

face so that the vertex in the oset faces is a quadrangle [

By choosing a

constant inclination angle we could guarantee the oset in a single vertex for all
faces and adapt the script to this particular situation

Addressing

All panels were identied by an address number composed by the line and the

row number (see gure 9.2.2).

Panel layout

They were laid out by lines on seven plywood panels (see gure 9.3.1 a)).

The fact that the basic geometry can be developed as a single, continuous surface
helped to organize the faces on the panels with a minimum of waste. This is an
important advantage for the economic construction of folded plate structures.

Tool path

The order of milling operations and the tool path were generated by a second

script (see gure 9.3.1 b)):


The faces had to be xed on the machine base so that they do not move when
they are cut out of the plywood panel. Therefore two drilling holes were dened
in the diagonal of the panel. The position of these holes had to be controlled so
that the screws that x the faces are not in the way of other milling operations.
Each side of the faces is milled in three runs. The number of runs is linked to
the tool size and the milling speed.
Three holes for dowel connections are drilled in the oblique sides. Their position is automatically xed in function of the length of the sides and in order to
keep a minimal distance to the edge. Due to their geometry, the parallel sides are
not accessible for the milling tool.

Machine code A script translates the tool path into the machine code (see gure 9.3.1 c)).
Milling The machine code is tested 50cm below the machine table and with low speed to
evaluate its correctness. The faces were milled within a day. Each face is marked
by its number (see gure 9.3.1 d)).

Assembling

The faces were assembled horizontally by lines (see gure 9.3.1 e) and f )).

They are joined by dowels and glue. Some screws had to be added to keep the
faces in place. Stickers were used to control the position of the faces during the
handling and the transport. The lines have been piled up and connected by dowels
drilled with a lamello machine. The folded plate structure has been transported
in two pieces that were assembled in place.

The scripts to generate the oset mesh, the tool path and the machine code were developed by Ivo Stotz
[Sto09]

9.3. FABRICATION AND ERECTION

215

a) panel layout

p1_t ool _1
P671002
N10 G0 G66 F2000 Z- 29
N15 G47
N20 T40 M6
N25 G47 A0 B0
N30 S16000 M3
N35 G49
N40 G54 G0 X0 Y0 Z80 A0 B0
N45 ( Cont our c ut of par t number : 12: 3)
N50 G0 X500. 8012 Y1272. 1528 Z55. 1753 A35. 984 B45. 851
N55 G1 X482. 0376 Y1297. 9939 Z24. 1753 F1000
N60 G1 X74. 5779 Y1002. 1306 Z24. 1753 F4000
N65 G1 X69. 7357 Y1008. 7993 Z16. 1753 F1000
N70 G1 X477. 1954 Y1304. 6625 Z16. 1753 F4000
N75 G1 X471. 7478 Y1312. 1648 Z7. 1753 F1000
N80 G1 X64. 2882 Y1016. 3015 Z7. 1753 F4000
N85 G1 X93. 3416 Y976. 2895 Z55. 1753 F4000
N90 G0 X88. 8791 Y1010. 6654 Z53. 1781 A90 B31. 1856
N95 G1 X70. 1155 Y1010. 6654 Z22. 1781 F1000
N100 G1 X70. 1155 Y221. 8432 Z22. 1781 F4000
N105 G1 X65. 2733 Y221. 8432 Z14. 1781 F1000
N110 G1 X65. 2733 Y1010. 6654 Z14. 1781 F4000
N115 G1 X59. 8258 Y1010. 6654 Z5. 1781 F1000
N120 G1 X59. 8258 Y221. 8432 Z5. 1781 F4000
N125 G1 X88. 8791 Y221. 8432 Z53. 1781 F4000
N130 G0 X94. 426 Y269. 1184 Z55. 8193 A- 28. 852 B- 51. 4372
N135 G1 X75. 6624 Y235. 0603 Z24. 8193 F1000
N140 G1 X483. 122 Y10. 5785 Z24. 8193 F4000
N145 G1 X478. 2798 Y1. 7893 Z16. 8193 F1000
N150 G1 X70. 8202 Y226. 2711 Z16. 8193 F4000
N155 G1 X65. 3727 Y216. 3832 Z7. 8193 F1000
N160 G1 X472. 8323 Y- 8. 0985 Z7. 8193 F4000
N165 G1 X501. 8857 Y44. 6367 Z55. 8193 F4000
N170 G0 X513. 4487 Y- 2. 6386 Z42. 8219 A90 B31. 1856
N175 G1 X494. 685 Y- 2. 6386 Z11. 8219 F1000
N180 G1 X494. 685 Y1306. 5286 Z11. 8219 F4000
N185 G1 X489. 8428 Y1306. 5286 Z3. 8219 F1000
N190 G1 X489. 8428 Y- 2. 6386 Z3. 8219 F4000
N195 G1 X484. 3953 Y- 2. 6386 Z- 5. 1781 F1000
N200 G1 X484. 3953 Y1306. 5286 Z- 5. 1781 F4000
N205 G1 X513. 4487 Y1306. 5286 Z42. 8219 F4000
N210 ( Cont our c ut of par t number : 12: 2)
N215 G0 X460. 9592 Y1759. 0555 Z56. 8654 A- 18. 414 B62. 4414
N220 G1 X479. 7229 Y1815. 4161 Z25. 8654 F1000
N225 G1 X72. 2632 Y1951. 068 Z25. 8654 F4000
N230 G1 X77. 1055 Y1965. 6127 Z17. 8654 F1000
N235 G1 X484. 5651 Y1829. 9608 Z17. 8654 F4000
N240 G1 X490. 0126 Y1846. 3236 Z8. 8654 F1000
N245 G1 X82. 553 Y1981. 9755 Z8. 8654 F4000
N250 G1 X53. 4996 Y1894. 7074 Z56. 8654 F4000
N255 G0 X43. 4832 Y1977. 5858 Z42. 8219 A90 B- 31. 1856
N260 G1 X62. 2469 Y1977. 5858 Z11. 8219 F1000
N265 G1 X62. 2469 Y1099. 8064 Z11. 8219 F4000
N270 G1 X67. 0891 Y1099. 8064 Z3. 8219 F1000
N275 G1 X67. 0891 Y1977. 5858 Z3. 8219 F4000
N280 G1 X72. 5366 Y1977. 5858 Z- 5. 1781 F1000
N285 G1 X72. 5366 Y1099. 8064 Z- 5. 1781 F4000
N290 G1 X43. 4832 Y1099. 8064 Z42. 8219 F4000
N295 G0 X56. 1307 Y1134. 1823 Z55. 1753 A35. 984 B- 45. 851
N300 G1 X74. 8943 Y1108. 3412 Z24. 1753 F1000
N305 G1 X482. 354 Y1404. 2044 Z24. 1753 F4000
N310 G1 X487. 1962 Y1397. 5358 Z16. 1753 F1000
N315 G1 X79. 7366 Y1101. 6725 Z16. 1753 F4000
N320 G1 X85. 1841 Y1094. 1703 Z7. 1753 F1000
N325 G1 X492. 6437 Y1390. 0335 Z7. 1753 F4000
N330 G1 X463. 5903 Y1430. 0455 Z55. 1753 F4000
N335 G0 X468. 0528 Y1395. 6697 Z53. 1781 A90 B- 31. 1856
N340 G1 X486. 8164 Y1395. 6697 Z22. 1781 F1000
Page 1

11:4

b) tool path

d) milling

c) machine code

e) panels ready for assembling

f) assembly

Figure 9.3.1. Integrated manufacturing

216

9. PLYWOOD PROTOTYPE 02

9.4. Discussion
The construction of the prototype showed the ability of the form generation method
to react to precise formal and fabrication conditions.
Even though the form of the prototype is unconventional and surprising, it does not
seem arbitrary.

The spectator can perceive that an inner logic underlies the geometry

without understanding it.

This confers on the object a particular, rational beauty (see

gure 9.4.1 and 9.4.2).


To control the general shape it is very useful to model a simplied form with the help
of the corrugation mid-line. The vertex type of the oset surface and the form of the faces
could be eciently controlled with the inclination angle and the maximal amplitude.
To fabricate and built complex folded plate structures, integrated manufacturing tools
are indispensable. They allow us to fabricate the irregular pieces in a economic way and
with high precision.
The assembly didn't reveal major diculties and the built form is very precise. The
exibility of individual pieces helps during the assembly.

Figure 9.4.1. Inside-outside

9.4. DISCUSSION

Figure 9.4.2. Prototype

217

CHAPTER 10

Tests with aluminum plates


10.1. Introduction
The investigations with aluminum plates were conducted to prepare a workshop, that

Russel Lovrige

of the LAPA/EPFL proposed to his students [

Lov08].

The topic of the

course was Material Logic. Starting from a construction material, the students had to
investigate the design parameters dictated by the material.

One of the materials the

students had to examine were Alucobond composite panels. The brief for the nal design
of the workshop was to build a simple pavilion out of Alucobond panels.
Alucobond is a facade sheet material composed of two thin sheets of aluminum and an
inner core of PE plastic with a total material thickness of 4mm. Thin aluminum sheets
are very ductile and can be easily deformed. It is the combination with the core that gives
the plates a remarkable stiness while having a very light weight.
The idea to use Alucobond panels and directly fold them like paper folding seemed
very natural. The goal of the tests was to investigate if folding at this scale is possible and
under which conditions.

Figure 10.1.1. Detail of a folded Alucobond plate


219

220

10. TESTS WITH ALUMINUM PLATES

10.2. Fabrication
We used two dierent geometries for the tests:
(1) A very simple geometry with parallel folds. The regular corrugation prole had
constant amplitude and inclination angle, with three concave and two convex
main-folds. The convex cross section prole had three edges. The 18 quadrangular
faces have an average size of

1800 cm2

(see gure 10.1.1).

(2) The second geometry was more complex in order to show the limits of folding
Alucobond plates (see gure 10.3.1). The corrugation prole of the parallel mainfolds had constant amplitude but unequal inclination angles. The main diculty
was given by the cross section prole. It describes an S-curve and has convex and
concave curvature.

The maximal amplitude of many edges corresponds to the

amplitude of the corrugation prole which means that the geometry has mainly
six-edge vertices. The number of faces is much higher than in the rst geometry
and size of the faces smaller.

56 cm2 and the biggest

The smallest of the

110

faces has a surface of

550 cm2 .

The geometry was designed in 3-dimensional space and then developed as a plane surface
whose size was adapted to the Alucobond panels (2500

1250 mm).

To be able to fold

the panels, they were carved with a conical tool which removed the outer aluminum sheet
and the core material along the fold edges. The drawing of the developed surface and the
indication of the carving depth were translated to a machine code with CAM software.
The aluminum panels were xed with tape to the machine table to be milled.
The rst geometry was easy to fold with two persons. As in paper folding the parallel
folds were folded rst. To bend the folds, the convex folds were supported with a timber
block near the vertex and reversed by pushing down between the two side-folds. To avoid
crumpling the vertices they were cut out with a small hole.
The second geometry was more dicult to fold mainly due to the size of the faces. One
main-fold broke because of the multiple inversions. Indeed at each bending point the fold
is reversed from concave to convex and the material becomes more brittle in the fold edge.
This time we didn't cut out the vertices . We were surprised that even six-edge vertices
could be folded properly.

10.3. Discussion
The test showed that Alucobond panels could be folded and used for the geometries
we design.

For reasonable face sizes, the folding is easy and the vertices can be folded

properly without breaking or crumpling. Even six-edge vertices can be folded properly.
This opens new perspectives for the form generation method we developed. Applications in interior design, furniture design and facade cladding can be foreseen. It would be
very interesting to test curved folds with Alucobond plates.

10.3. DISCUSSION

Figure 10.3.1. Milling and folding of Alucobond plates

221

Conclusions and outlook

10.4. Conclusions
Folded plate structures dene structure, space and envelope in a single surface. The
separation between engineering and architecture does not apply, folded plate structures
are both, structure and space.

Fascinated by their ambivalent character we decided to

investigate folded plate structures in an approach that combines intuitive experimentation


and rational analysis in order to provide a design method which generates folded plate
geometry's in 3D modeling software. With the help of this method architects and engineers
can modify local and general parameters in function of spatial, constructive and structural
constraints.
By experimental paper folding we chose three folding patterns which seemed particularly adapted to folded plate structures:

Hexagonal pattern
Herringbone pattern
Diagonal pattern

The developed patterns can be decomposed in longitudinal strips, a decisive advantage


for construction with timber panels which generally have an elongated size (see chapter 9,
gure 9.3.1 a) and appendix, gure 12.3.2).
The basic form of these patterns is a

simply-corrugated surface

which is dened by its

corrugation prole. We distinguish two types of simply-corrugated surfaces:


Parallel folds A series of concave and convex folds, parallel to each other dene a straight
or a cylinder surface.

Oblique folds

The folds are not parallel. The general shapes are straight surfaces, cylinder

surfaces and ruled surfaces.

With oblique folds, the shape of the corrugation

prole varies but the inclination angle of its faces stays constant.

Simply-corrugated surfaces can be bent by

reverse folds.

One part of the simply-corrugated

surface is reected o a reection plane positioned across the simply-corrugated surface.


A system of orthogonal projection with reection planes perpendicular to the frontal plane

xz

allows us to dene the bending of the simply-corrugated surfaces by a

prole.

cross section

It denes the bending angle of the reverse folds. The reection planes are given by

the exterior angle bisector of the cross section prole edges.


The position of the simply-corrugated surface relative to the frontal plane

xz

and

the inclination of the corrugation prole edges dene whether the geometry is completely
foldable or not:

Parallel

Folds parallel to the projection plane

xz

can be completely folded when the edges

of their corrugation prole has equal inclination angles.

Oblique

Folds oblique to the projection plane cannot be completely folded.

Hereby, folded plate geometries can be designed with two proles:

corrugation prole
cross section prole

10.4. CONCLUSIONS

225

The cross section prole allows design of the general shape of the folded plate geometry.
The general shape can be locally modied by the shape of the corrugation prole. The
folded plate geometry becomes helical if the simply-corrugated surface is placed obliquely
to the frontal projection plane

xz

The combination of the two proles can generate a great variety of forms.
The orientation of the cross section prole edges, determines the pattern type.

We

distinguish two main patterns:

Hexagonal pattern It is generated by a convex polygonal cross section prole1.


Herringbone pattern It is generated by a zig zag cross section prole.
To each cross section prole corresponds a maximal amplitude.

If the amplitude of the

corrugation prole corresponds to the maximal amplitude of the cross section prole, fouredge vertices become six-edge vertices, and quadrangular faces become triangular.
We propose a method to control the cross section prole amplitude by using the incircle for convex polygonal cross section proles, and the ex-circle for zig zag cross section
proles.

This enables design of cross section proles with constant amplitude and thus

provides control of the pattern type.

The control of the cross section prole amplitude

is of particular importance: it allows us to generate folded plate structures with regard


to structural depth. It also enables design of cross section proles for corrugations with
irregular forms by considering their maximal amplitude.
The investigation concerning the surface oset has shown which parameters determine
the vertex conguration of the oset surface. Only symmetric four-edge vertices can be
oset such that the edges of the oset surface meet in a single vertex. In general, geometries
with four-edge vertices are to be preferred even though the vertex conguration in the oset
surface of asymmetric and oblique folds is altered. With six edge vertices, only the oset
of symmetric folds shows a feasible vertex conguration in the oset surface.
The geometrical investigations dened a method of generating folded plate structures
with a corrugation prole and a cross section prole. This enables the design of various
types of folding patterns, in particular, Diamond patterns, Herringbone patterns, and with
restrictions, Diagonal patterns.
The method is close to paper folding where completely closed, simply-corrugated surfaces are bent, and then redeployed in space.

Paper folding has the disadvantage that

the bending angles, and therefore the general form, changes during the deployment of the
surface. By means of the cross section prole, the mid-line of the general shape, irregular
and oblique corrugated surfaces can be directly folded in space into their nal position.
This allows generatation of geometries which cannot be created by intuitive paper folding,
because they are not completely foldable.
1

The diagonal pattern can be considered as a special case of the hexagonal pattern where a simplycorrugated surface is placed oblique to the frontal projection plane xz . However this method only allows
representation of diagonal patterns where the diagonals are continuous straight lines.

226

Due to the reduction to two sets of parameters, the folded plate geometries can be
rapidly generated and modied. A great variety of forms can be generated. General shape
and corrugation can be adapted to specic conditions of a project. For example, amplitude
of corrugation can be increased at the edge to reinforce the border of folded plate structures.
This variability is very attractive because it allows the engineer as well as the architect to
act on project specic conditions by modifying the parameters of the folded plate structure
without alerting its expressive character.
We showed the consequences of specic parameter variations and their limits.

This

allows the designer to be conscious about the implications of certain decisions in the design
process right from the beginning.
The proposed design method can be applied in any 3D CAD software.

The reverse

side of the simplicity and variability of this method is that the general form is limited to
cylinder surfaces. Geometries based on multiple patches can create doubly-curved surfaces,
but they are less easy to handle and to modify.
The construction of physical models and prototypes was of great importance for the
comprehension of the proposed geometries. Building the geometries generated in 3D software, with timber panels, facilitated the verication of their the exactitude and gave us
awareness of problems we did not suspect. Particularly, questions about the geometry of
the joints between the plates became obvious.
The feasibility of folded plate structures with timber panels based on the proposed
methods has been shown.

Fabrication and assembling were precise.

The connections

between the panels are quite exible, which helps assmbly and indicates that it seems
reasonable to consider them as hinges for structural calculations.

10.5. Outlook
In further research we aim to implement the method of generating folded plate structures with a corrugation prole and a cross section prole in parametric software. This
would accelerate the design process and improve its handling. The implementation in a
parametric software would also open up the possibility of a connection with calculation
software in order to optimize the structural behavior of folded plate structures. For folded
plate structures with triangular faces, a parametric representation could also allow us to
deform the general shape, similar to the deformations that are possible with folded paper
models.
The currently proposed structures are single patch geometries.

The combination of

multiple patches has to be investigated in order to create doubly-curved surfaces. Particularly the methods proposed by

Thonon [Ton91, Ton93] could be useful in combination

with parametric software.


The Diamond patterns and the Diagonal patterns which we can generate are particular
cases of the geodesic patterns described by

Delarue [Dea93].

elaborate a more general design method for geodesic patterns.

It would be interesting to

10.5. OUTLOOK

227

The proposed method can generate curved folds. It would be interesting to investigate
the construction of curved folds made with a series of vertical planks, joined with linear
connectors or glued together.
The comparison between the deformation of one prototype with structural calculations
showed that the simulation of their structural behavior has to be improved.

The load

test also showed the importance of the connections which have to be examined carefully
for further realizations. The results of the load test engaged new engineering research for

HW07, HW08b, HW08a, Hah09].

folded plate structures [

We are convinced that full scale folded plate structures with timber panels are feasible.
Future projects will contribute to the constructive development of folded plate structures
(see appendix chapter 12). In particular the joints between the panels, the integration of
thermal insulation, and the exterior cladding, have to be developed in relation with specic
projects and in collaboration with engineers and the involved craftsmen.

Bibliography
[AG05]
[Alb52]
[BM02]
[BV91]
[BW07]

[BW08]
[BW09]
[CB97]
[Cip01]
[Con89]
[Dea93]
[Del80]
[Del94]

[DF02]
[DN02]
[Eng89]
[FF99]
[Fro78]
[HA05]
[Hah09]
[Har57]
[Hob93]

H.G. Ambrozy and Z. Giertlov. Holzwerkstoe, Technologie Konstruktion Anwendung.


Springer, Wien, 2005.
J. Albers. Concernig fundamental design. In Bauhaus 1919-1928, pages 114121. Branford,
Boston, 1952.
F. Bucci and M. Mulazzani. Luigi Moretti, Works and Writings. Princeton Architectural Press,
New york, 2002.
H. Buri and N. Vaucher. De la coupe au plan, entre cinma et architecture. Master's thesis,
EPFL, Lausanne, 1991.
H. Buri and Y. Weinand. Uebersicht Massivholzplatten. In 39. Fortbildungskurs Schweizerische
Arbeitsgemeinschaft fr Holzforschung, pages 6384, Dbendorf, 2007. SAH Schweizerische Arbeitsgemeinschaft fr Holzforschung.
H. Buri and Y. Weinand. ORIGAMI - Folded Plate Structures, Architecture. In 10th World
Conference on Timber Engineering, 2008.
H. Buri and Y. Weinand. Gefaltet. TEC 21, (8):1822, 2009.
C. Cerliani and T. Baggenstos. Sperrholz Architektur. Baufachverlag Lignum, 1997.
B. A. Cipra. In the Fold: Origami Meets Mathematics. SIAM News, 34(8):14, 2001.
E. Consemller. Fotograen Bauhaus Dessau. Schirmer/Mosel, Mnchen, 1989.
J.-M. Dealrue. Minimal folding tensigrity congurations. Bulletin of the international association for shell and spatial structures IASS, pages 211220, 1993.
J.-M. Delarue. Faltstruckturen (Forschungsperspektiven). In IL 27 Natrlich bauen, Symposiumsbericht, 1980.
J.-M. Delarue. Generation of geodesic folding patterns. III International Symposium of the

Sonderforschungsbereich 230; Evolution of natural structures; principles, strategies and models


in architecture and nature, (III):25  30, 1994.

S. D. De Focatiis, D. S. A .and Guest. Deployable membranes designed from folding tree leaves.
Phil. Trans. R. Soc. Lond. A, 2002.
M. Dunky and P. Niemz. Holzwerkstoe und Leime. Springer, Berlin, Heidelberg, New York,
2002.
P. Engel. Folding the Universe: Origami from Angelsh to Zen. Vintage Books, New York,
1989.
J. Fiedler and B. Feierabend. Bauhaus. Knemann, Kln, 1999.
P. Frostick. Antiprism based form possibilities for folded surface structures. Architectural Science Review, 21:5967, 1978.
G.W. Hunt and I. Airo. Twist buckling and the foldable cylinder: an exercise in origami.
International Journal of Non-Linear Mechanics, 40:833843, 2005.
B. Hahn. Analyse und Beschreibung eines rumlichen Tragwerks aus Massivholzplatten. Master's thesis, TU Dresden and EPFL ENAC IBOIS, 2009.
G.P. Harsdrer. Vollstndiges und von neuem vermehrtes Trincir-Buch. Frst, Nrnberg,
1657.
C. Hoberman. Curved pleated sheet structures, 1993.

229

230

BIBLIOGRAPHY

D. A. Human. Curvature and Creases: A Primer on Paper. IEEE transactions on computers,


c-25(10):10101019, 1976.
[Hun05]
Hundegger. Hundegger Maschinenbau, product information Gantry CNC Milling system, 2005.
[Hux60]
A. L. Huxtable. Pier Luigi Nervi. Il Saggiatore, Milano, 1960.
[Huy72]
P. Huybers. See-Through Structuring a method of construction for large span plastic roofs. PhD
thesis, Technische Hogeschool Delft, 1972.
[Huy99]
P. Huybers. Prism based structural forms. Engineering Structures, 23:1221, 1999.
[HvdE89] P. Huybers and G. van der Ende. Uniform Polyhedra for Building Structures. In G. Danvas
and D. Nagy, editors, Symmetry of structure, interdisciplinary Symposium, pages 233236,
Budapest, 1989.
[HVR70] S. Hirshen and S. Van Ryn. Zusammenfaltbare und transportable Unterkunft fr Ernetearbeiter
in Kalifornien. Werk, (5):304305, 1970.
[HW07]
M. Haasis and Y. Weinand. Origamifaltwerke, Neue Anwendung fr Brettsperrholzplatten. In
Praktische Anwendung von Massivholzplatten, pages 175181, Dbendorf, 2007. SAH Schweizerische Arbeitsgemeinschaft fr Holzforschung.
[HW08a] M. Haasis and Y. Weinand. ORIGAMI - Folded Plate Structures, Engineering. In 10th WCTE,
2008.
[HW08b] M. Haasis and Y. Weinand. Versuche an Verbindungen fr Faltwerke aus Brettsperrholzplatten.
In Statusseminar Schweizerische Arbeitsgemeinschaft fr Holzforschung, 2008.
[INI+ 92] M. Ishinabe, Y. Nishimura, K. Imazu, Y. Kobayashi, and H S Matsubayashi. Packing can, 1992.
[Jac05]
S. Jacob. Faltwerk fr alle Tne. Bauen mit Holz, pages 2024, 2005.
[Jon62]
C. Jones. Marcel Breuer 1921-62. Vincent, Fral & Cie, Paris, 1962.
[Kle98]
G. Kley. Holz-Faltwerke als Dachkonstruktion. Bauen mit Holz, (6):1721, 1998.
[Kli97]
D.H. Kling. Doubly periodic at surfaces in three-space. PhD thesis, New Brunswick Rutgers,
The State University of New jeresy, 1997.
[Kli05]
D. H. Kling. Patterning technology for folded sheet structures, 2005.
[Kol03]
B Kolarevic, editor. Architecture at the digital age design and manufacturing. Taylor &Francis,
New York and London, 2003.
[KR78]
M. Kozel and C. Riepl. Computer aided investgation of a system of irregular antiprismatic
folded surfaces. Architectural Science Review, 21:6872, 1978.
[Kre02]
B. Kresling. Folded Tubes as Compared to Kikko (Tortoise-Shell) Bamboo. In Origami3. A K
Peters, Natick, 2002.
[Kre08]
B. Kresling. Natrural twist bucklingin shell: from the hawmoth's bellows to the deployable
Kresling pattern and cylindr Miura-Ori. In Proceedings of the 6th International Conference on
Computation of Shell and Spatial Structures IASS ICAM, 2008.
[Leb80]
J. S. Lebedev. Stand und Probleme der Architekturbionik in der UDSSR. In IL 27 Natrlich
bauen, Symposiumsbericht, pages 258267, 1980.
[Lei04]
K. Leitner. Tragkonstruktionen aus plattenfrmigen Holzwerkstoen mit der TEXTILEN
FUGE. PhD thesis, RWTH Achen, 2004.
[Lov08]
R. Lovridge. DD+P Spring 2008 - Material Logic, 2008.
[Miu70]
K. Miura. Proposition of Pseudo Cylindrical concave polyhedral shells. 1970.
[Miu89]
K. Miura. Folding a plane - scenes from nature, technology and art. In G Danvas and D Nagy,
editors, Symmetry of structure, interdisciplinary Symposium, pages 391394, Budapest, 1989.
[Miu02]
K. Miura. The application of Origami Science to Map and Atlas Design. In Origami3. A K
Peters, Nantick, 2002.
[Mor52]
L. Moretti. Struttura come Forma. Spazio III, III:2130, 110, 1951-52.
[NPW06] J. Natterer, C. Pirazzi, and Y. Weinand. Analyse comparative d'une structure Origami. Technical report, EPFL IBOIS, Lausanne, 2006.
[Huf76]

BIBLIOGRAPHY

231

[PAHK07] H. Pottmann, A. Asperl, M. Hofer, and A. Kilian. Architectural Geometry. Bentley Institute
Press, 2007.
[PLW+ 07] H. Pottmann, Y. Liu, J. Wallner, A. Bobenko, and W. Wang. Geometry of multi-layer freeform
structures for architecture. In Proc. SIGGRAPh, volume 26(3), 2007.
[PW06]
C. Pirazzi and Y. Weinand. Structures spatiales en bois: analyse structurelle d'une coque plisse
en bois avec le logiciel de calcul SAP2000 NL V9.16. Technical report, EPFL ENAC IBOIS,
2006.
[Qua74]
A. Quarmby. The plastic architect. Pall mall press, 1974.
[Sch04]
G. Schickhofer. Skriptum zur Lehreveranstaltung Holzbau. TU Graz, Graz, 2004.
[Sed75a] V. Sedlak. Folded Surface Structures. PhD thesis, University of Surrey, departement of civil
engineering, Surrey, 1975.
[Sed75b] V. Sedlak. Paperboard Structures. In Proc 2nd Int Conf on Space Structures Univ of Surrey,
pages pp780793, 1975.
[SF00]
A. Sogame and H. Furuya. Conceptual study on cylindrical deployable space structures. In
S Pellegrino and S D Guest, editors, IUTAM IASS Symposium on deployable structures: Theory
and applications, pages 383392, 2000.
[Sie60]
C. Siegel. Strukturformen der modernen Architektur. Calwey, Mnchen, 1960.
[SS01]
A. Sogame and J. Saito. Deployable Structure, 2001.
[Sto09]
I. Stotz. Iterative Geometric Design for Architecture. PhD thesis, EPFL, ENAC, IBOIS, Lausanne, 2009.
[Tac09]
T. Tachi. Generalization of Rigid Foldable Quadrilateral Mesh Origami. In Proceedings of the
internaltional Association for Shell and Spatial Structures (IASS) Symposium 2009, pages 2287
2294, 2009.
[Ton91]
O. L. Tonon. Geometry of spatial folded form. International Journal of Space Structures,
6(3):227240, 1991.
[Ton93]
O. L. Tonon. Geometry of the spatial folded form. In Space structures 4, page 20242052. Thomas
Telford, London, 1993.
[Tor61]
E. Torroja. Die Logik der Form. Callwey, Mnchen, 1961.
[Tre08]
J.-C. Trebbi. l'art du pli. Editions Alternatives, Paris, 2008.
[Vas05]
N. Vasseur. Les Plis. Seuil, Paris, 2005.
[VlD56]
E. Viollet-le Duc. Dictionnaire raisonn de l'architecture franaise du XIe au XVIe sicle, 1856.
[Voi07]
P. Voigt. Die Pionierphase des Bauens mit glasfaserverstrkten Kunststoen (GFK) 1942 bis
1980. PhD thesis, Bauhaus Universitt Weimar Fakultt Gestaltung, 2007.
[Wal09]
Walsermuseum. St.Anna Kapelle, Faschinajoch, 2009.
[YK03]
Z. You and K. Kuribayashi. A Novel Origami Stent. In Summer Bioengineering Conference,
pages 02570258, Florida, 2003.
[Zei93]
F. Zeier. Papier, Versuche zwischen Geometrie und Spiel. Haupt, Bern, 1993.
[Zod73]
Zodiac. Piano. Zodiac Light weight structures, 22:130131, 1973.

Appendix

CHAPTER 11

Illustrations of folded-plate geometries

Figure 11.0.1. Macro-form variation


235

236

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

Figure 11.0.2. Three folded plate geometries with identical general shape,

a S-curve. The amplitude is varies: The smaller the amplitude, the closer
the shape becomes to the S-curve

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

a)

z
y

z
x

b)

z
y
x

y
x

z
x

Figure 11.0.3. Regularly-corrugated surface parallel (a) and oblique (b)

to the frontal plane


angles.

xz .

The cross section prole has constant bending

237

238

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

z
y

z
x

Figure 11.0.4. Regularly corrugated surface oblique (b) to the frontal

plane

xz

In convex polygonal cross section proles with constant bending angle

there is a

close relationship to the zig-zag cross section prole. Such a geometry can be decomposed
in three strips following three directions. The projection of the mid-line of one strip (green)
corresponds to a convex polygonal cross section prole. The projection of the mid-line of
the two other strips (red and blue) corresponds to a zig-zag polygonal cross section prole.
In gure 11.0.3 a) The green strip is parallel to the frontal plane
to a convex polygonal cross section prole.

xz

and corresponds

The red and the blue strip correspond to a

zig-zag cross section prole and are oblique to the frontal plane
In gure 11.0.3 b) all strips are oblique to the frontal plane

xz .
xz .

In gure 11.0.4 the green strip (convex polygonal cross section prole) is oblique to the
frontal plane

xz

and so is the blue strip (zig-zag cross section prole). The red stripe is

parallel to the frontal plane

xz

and corresponds to a zig-zag cross section prole.

For convex polygonal cross section proles with constant bending angle

it is possible

to design oblique folds with the edge of the folded plate geometry parallel to the frontal
plane

xz .

The rotation angle between the frontal plane

xz

and the main crease edge

can be determined by designing a single strip of related the zig-zag cross section prole.

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

a)

x
b)

y
x

Figure 11.0.5. Tennis hall: a) Clearance diagram b) folded plate geometry

with a convex polygonal cross section prole and a corrugation prole with
regular inclination angles.

239

240

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

a)

x
b)

y
x

z
x

y
Figure 11.0.6. Tennis hall: a) folded plate geometry with a convex polyg-

onal cross section prole and a corrugation prole with steeper inclination
angles on the border, in order to reinforce the edges of the folded plate
structure. b) folded plate geometry with a zig-zag cross section prole and
the same corrugation prole as gure 11.0.6a).

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

Figure 11.0.7. Tennis hall: exterior and interior perspective. The geom-

etry is the one of gure 11.0.6b).

241

242

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

a)

A1

I1

Maxiumum vertical deformation z: 3,3 mm

b)

A2

A1

I1

I1

Maxiumum vertical deformation z: 2.2 mm

c)

A1

A1

I2

I1

Maxiumum vertical deformation z: 1,9 mm

Figure 11.0.8. Inuence of the corrugation prole on structural strength:

A, inclination angle ,
A and the inclaination angle

geometry and vertical deformations. a) Amplitude


and interval

are constant. b) The amplitude

of the border edges is increased, interval

angle

is constant c) The inclination

of the border edges is increased and their interval diminishes

amplitude

stays constant.

I,

the

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

a)

b)

c)

Figure 11.0.9. Modulation of the macro form a) Polygonal corrugation

mid-line. b) Instead of a simply-corrugated surface, a curved herringbone


pattern was reected about the planes dened by the cross section prole.
c) Irregularly curved corrugation prole.

243

244

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

Figure 11.0.10. Illustrations for dierent types of use with the geometry

of gure 11.0.9.

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

x
x

y
x developped
Figure 11.0.11. Folded plate geometry based on simply-corrugated sur-

face following a ruled surface.

245

246

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

Figure 11.0.12. Studies for a temporary concert hall in Verbier.

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

y
x

y
x

y
x
Figure 11.0.13. Variations of herringbone patterns.

247

248

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

Figure 11.0.14. Herringbone pattern with edged and curved corrugation prole.

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

a)

b)

x
Figure 11.0.15. a) Study for a curved wall behind a reception desk of a

hotel. b) Cylinder with eight-edge vertices (see section 6.3.2.6).

249

250

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

Figure 11.0.16. Studies for lampshades with curved folds.

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

z
x

z
x
Figure 11.0.17. Cross section prole variations: Combination of convex

and Zig-zag cross section prole with dierent limit situations.

251

252

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

a)

b)

Figure 11.0.18. Cross section prole variations: a) coered diamond pat-

tern b) herringbone pattern.

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

y
x developed
Figure 11.0.19. Convex polygonal cross section prole: the corrugation

amplitude is bigger than the maximal amplitude of the cross section prole
(see section 6.3.1.5).

253

254

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

Figure 11.0.20. In these examples the simply-corrugated surface has been

replaced by straight herringbone patterns. It is interesting to note that the


patterns of the folded plate geometry are similar to those of gure 11.0.19
(see section 6.3.1.5).

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

Figure 11.0.21. Studies for a gymnasium, version a): The pattern is com-

posed of two patches in order to diminish the width (amplitude) of the


vertical elements at their base.

255

256

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

Figure 11.0.22. Studies for a gymnasium, version b).

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

257

z
x
y

z
x

z
x
y

x developed
Figure 11.0.23. Multi-patch geometries based on torus surfaces (herring-

bone pattern).

258

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

a)

z
x

b)

z
x
y
Figure 11.0.24. Multi-patch geometries: a) Torus surface (hexagonal pat-

tern) b) Rotation about a vertical axis (herringbone pattern)

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

z
x
y

z
x
y

z
y
x

Figure 11.0.25. Multi-patch geometries: Torus surface with changing radius.

259

260

11. ILLUSTRATIONS OF FOLDED-PLATE GEOMETRIES

zy
x

y x

z
x
y

z
x cross section profile

z
y corrugation profile
Figure 11.0.26. Example of a geometry with asymmetric corrugation

where the shift of the main-fold edge in the oset surface results in an
interesting tectonic.

CHAPTER 12

The chapel of St.Loup


12.1. Introduction
The chapel of St. Loup is the rst full scale construction with a design based on the
methods for generating folded plate geometries developed at the laboratory for timber
construction IBOIS. Convinced that folded plate structures with cross-laminated timber
panels can be realized, we were looking for a partner to build a full-scale building since
spring 2007.

To transfer the knowledge of the laboratory to the construction site we

founded a consulting company for architecture and engineering:

Weinand, Architecture, Engineering and Production Design.

Shel, Hani Buri, Yves

In the end of 2007 we found

a partner on an unexpected side: the deaconess's of St.Loup. In spring 2007 they organized a competition to transform and renovate their nunnery. The team

and Bureau d'architecture Danilo Mondada

Localarchitecture

won the competition. Their project foresaw

important transformations to the chapel which meant that the deaconesses needed a temporary place for worship during the building work which was expected to last 18 months
[

BW08, BW09].

a)

b)

c)

Figure 12.1.1. a) Paper folding of the chapel b) plan of the Saint chapel

Paris [

VlD56] c) Chapel St.Anna, Faschinajoch [Wal09]


261

262

12. THE CHAPEL OF ST.LOUP

How to reconcile the claim for a pragmatic and reasonably priced solution to be designed and built in very short time, with the exceptional spatial and symbolic quality
required for a place of worship?
Particularly interested and experienced in timber construction,

Localarchitecture

pro-

posed a collaboration with the laboratory for timber construction IBOIS of EPFL and its
start up company

Shel.

One of their research topics, folded plate structures for timber

panels, seemed particularly adapted to achieve high architectural quality, rapid execution
and reasonable costs. Already the very rst paper models convinced the sister community
of the appropriateness of such a solution.

Within a few weeks the team developed the

design destined to shelter the temporary chapel.


St.Loup is a place at the base of the Jura: an oblong clearing, oriented east-west, forms
its own microcosm with a quiet atmosphere. At the eastern end of the clearing the hospital
of St.Loup and the buildings of the deaconesses form a large semi-circle with, in its center,
a walnut tree. It is next to this tree that the temporary chapel forms the new community
center during the transformation works.
The project interprets the spatial and structural characteristics of a traditional chapel:
a simple rounded nave, structure and light that gives a rhythm to the space, a clear axial
orientation of the space to the chancel, an entry porch as a space of transition from outside
to inside, and a belfry that distinguishes the religious building.

12.2. Form Generation


The geometry of the chapel integrates spatial, structural, constructive, acoustic and
lighting constraints in a single, synthetic form. The following parameters determined the
shape of the chapel:

The form should express a certain simplicity and self evidence, be economic and
had to be rapidly assembled.

Therefore a very basic, trapezoidal cross section

prole (red) with three segments was chosen.

The form should recall some characteristics of a church space; a simple rounded
nave. To do so, the corrugation mid-line (blue) is slightly bent. This compresses
the folded surface and the space of the nave raises up in direction of the chancel
(see 12.2.1). The progressive transition from the horizontal to the vertical gives
the room a clear focus and meaning: it evokes the transition from an earthbound,
human condition to a spiritual quest. On the exterior the rst crease denes an
entry porch and the rising tip on the other end recalls a small belfry (see gure
12.1.1c)).

The geometry of the chapel should dene simultaneously dene space, enclosure
and structure: a series of parallel folds give the surface the necessary depth to be
self supporting (see gure 12.2.1b)). As in traditional churches the structure has
an important presence in space. The rhythm of the columns is taken up by the
folds and organizes the nave (see gure 12.1.1b)).

12.2. FORM GENERATION

263

In a second phase the parallel corrugation was modied and became oblique.
Therefore the method of design oblique folds with a ruled surface was used (see
section 4.3.2) The convex folds are now oblique whereas the concave folds stay
parallel to each other: wall and roof are modulated by deep and small folds and
the roof creases become transversely inclined (see gure 12.2.1c)).

The sloped

a)

b)

c)
Figure 12.2.1. Geometry of the chapel:

corrugation prole (blue)

cross section prole (red) and

264

12. THE CHAPEL OF ST.LOUP

roof creases allow the rain water to be evacuated. The irregular inclination of the
surfaces improves the acoustics and the lighting of the chapel. Light entering from
the gable facades reects o the oblique surfaces and traces a slightly irregular
and subtle succession of shadows on the timber plates.

12.3. Structure and construction


The simplicity of the detailing, a high degree of prefabrication, and a direct data
transmission from architects to engineers and then to producers, enabled the chapel to be
realized in a very short time. The calculations with a nite element program showed that
the structure could be built with cross laminated timer plates of 40 mm thickness for the
walls and 60mm for the roof (see gure 12.3.1 a)). The plates were fabricated and milled
in the factory ( see gure 12.3.2). They were assembled on place with folded steel plates
and screws within ten days (see gure 12.3.1b) and 12.3.3)).

12.3.1. Structural design.

To analyze the mechanical behavior of the folded plate

structure developed in the form-nding process, the digital le from the modeling tools
was directly imported into the calculation program Diamond (Buildsoft). The supporting
structure needed to be constructed with cross-laminated timber panels with thicknesses of

40 mm

for vertical and

60 mm

for the horizontal panels. The appropriate properties were

introduced into the calculation software. The structural analysis conrmed the thickness
of the plates and the poly-surface in the modeling tool could be oset.
In the calculation the edges of the folds were simulated as hinges. Despite the rotational freedom of all joints the overall stiness of the structure is given by the specic
spatial arrangement of the elements.

Only the translational freedom (shift parallel and

perpendicular to the edge) were blocked in the model. In reality bending moments occur
along the folds, since the panels are connected with thin steel plates.
Depending on the rotation direction of the moments, varying lever arms occur caused
by the unilateral connection of the timber panels with steel plates. However these local
bending moments were neglected in this model. From the static software was determined
both the deformations, and the internal forces. The 60 mm thick plates of the roof bear
more than about

9m span,

representing an equivalent slenderness of

1/150.

The enormous

eciency of folded plate structures is evident by this very high slenderness. The point with
the largest deformation of the entire structure is located on the outer edge of the folded
plate structure directly above the entrance. Since this edge is not supported by further
folds, the edge is free and therefore not stiened.

12.3.2. Oset.

The oset was designed manually in a 3D CAD software mainly be-

cause of the oblique folds and the changing inclination angles of the faces, but also because
of the dierent thicknesses of horizontal and the vertical plates. The small number of faces
(42) made it more rational to design the oset by hand than to develop a script adapted
to this particular conguration.

On the small side of the chapel the inclination angles

strongly vary and as a consequence the main-fold edges of the oset surfaces are shifted

12.3. STRUCTURE AND CONSTRUCTION

265

as described in 7.2.3. Even though locally the shift is important, it doesn't deteriorate the
perception of the general shape of the chapel.

1700.00

3400.00

Type 5

pe
Ty

axe du pli

3000.00

1200.00

arrtes ^ laterales 60_40


175 clous par ml
ep 3mm
48 ml

1800.00

pe

2400.00

Ty

axe du pli

1700.00

1600.00

3200.00

axe du pli

Type 3

2400.00

1200.00 1200.00

arrtes V en toiture 60_60


arrtes V verticales 40_40
150 clous par ml
p.= 3mm
32 ml

Type 1

Type 2

arrtes ^ en toiture 60_60


d 150 clous par ml
ep 2mm
41 ml

1200.00 1200.00

Type 4

1200.00 T3
1200.00 T3

Type 2

Type 4
1200.00 T3

Type 1

Type 4

arrtes ^ verticales 40_40


d 150 clous par ml
p.= 2mm
56 ml

1600.00

Type 1

Type 2

Type 1

Type 2
1200.00 T3

Type 1
Type 2
Type 1

Type 2

Type 2

Type 4

1200.00 T3

Type 2

Type 4
1200.00 T3

Type 1

1200.00 T3

Type 2

Type 1

Type 2

Type 1
Type 2
Type 1

Type 2

Type 2

Type 4

1200.00 T3

Type 2

Type 1

Type 2
1200.00 T3

Type 2

Type 4
1200.00 T3

Type 2

Type 1

arrtes V verticales 40_40


150 clous par ml
p.= 2mm
81 ml

1199.98 T3

1200.00 T3

(ECH.: 1/10)

Type 2

1200.00 T3 T2 1200.00 T3

Type 2

1200.00 T3

1200.00 T3

Type 1

Type de tle

(ECH.: 1/100)

1200.00 T3

1199.99 T3

Faade

pe
5

1200.00 T3

Ty

1200.00 T3

Toiture

1200.00 T3

1199.99 T3

pe

1200.00 T3

Ty

Type 1

Faade

1200.00 T3

Type 1

Situation des tles sur les arrtes

axe du pli

Figure 12.3.1. a) vertical deformation of the structure b) steel plates for

the joints

axe du pli

266

12. THE CHAPEL OF ST.LOUP

12.3.3. Fabrication.

The chapel was entirely designed in a 3D CAD software includ-

ing the oor panels, the cladding panels, the support beams and the protecting battens of
the gable facades. The geometry was transferred to the carpenter's software who transferred it without modications to the panel fabricator.

Because the geometry can be

developed as a continuous surface, we could propose a panel layout with a minimum of


waste to the fabricator.

Indeed during the design of the geometry we had already con-

sidered the panel size of the fabricator. Furthermore all concave folds are parallel, which
allows one to package two adjoining panels in a rectangular form that doesn't exceed the
panel size of the fabricator (see gure 12.3.2).

12.3.4. Construction.
on a stabilized ground.

The chapel is supported by a series of concrete bricks lying

Four punctual concrete foundations at the edges of the chapel,

anchor the building to the ground. A grid of longitudinal timber girders supports the oor
panels (CLT

40 mm

) The edge girders follow the zig-zag form of the corrugation. They

are connected with the oor panels and the bricks by steel anchors. The
panels are screwed to the edge girders.

40 mm

thick wall

Floor panels and edge girders have been milled

with the inclination angle of the wall panels. The upper edge of the wall panels supports
the

60 mm thick roof panels.

All panels are joined on the exterior of the building by

2 mm

thick metal plates. They are standard timber connections, plates with regular holes for
nails or screws, that are folded with the correct inclination angle. The width of the plates
varies in function of the curvature of the folds in order to guarantee a correct distance
of the screws to the edge of the timber panels.

Plates for convex folds are larger than

those for concave folds. The crease of the side fold plates is asymmetric because of the
superposition of the roof panels to the wall panels. Screws connect steel plates and timber

panneaux verticales 40mm 175m2 net

panneaux de toiture 60mm 151m2 net

panneaux de plancher 40mm 155m2 net

12864

8601

8698

2250

2809

2969

6849

10119
2250

2715

2906

10419

9366

11030
2250

2713

2789

9606

8442

11744

10860

2250

2778

2904

10409

8397

2250

2818

2927

12134

8166

12312
2250

2828

2961

11087

12181

11725

Figure 12.3.2. Developed surface and panel layout for the fabrication

2753

2967

1736

13343

12.3. STRUCTURE AND CONSTRUCTION

panels at a regular distance

267

. The advantage to these kind of joints is that the connectors

can be distributed along the whole fold edge. As a consequence, the stress can be spread
over a large number of connectors instead of being concentrated in a single point as in
linear frameworks. The inside of the structure is free from connectors. The panel surface
is visible and not treated: Structure, form and internal lining are constituted of a single
element.
The structure is covered by a roof membrane that protects the structure against rain
and humidity. The exterior boarding is made of

18 mm

thick multilayer panels screwed

to vertical battens. The joints between the boarding panels are open and the rain water
is drained on the roof membrane along the slope of the structural panels. The boarding
panels are coated with a copper gray glaze in order to prevent an unequal graying.

12.3.5. Assembly.

The mason prepared the foundation bricks perfectly horizontal

so that oor girders and panels could be rapidly laid out.

The structural panels were

fabricated and milled in the factory and delivered to the construction site with their nal
shape.

To manipulate the panels they were equipped with threaded bolts which allow

xation of a steel hanger. First, three wall panels were xed to the edge girders on each
side.

To x them on the girder they were lifted with a crane.

As soon as two panels

formed the rst crease they started to stabilize each other. They were adjusted and held in
position with the help of telescopic bars. Secondly, the roof panels were xed onto the wall
panels. The steel plates for the connections were xed to the panels on the ground. This
helped to position the panels because they could be leaned onto the preceding panels along
the main-fold. Again the adjustment of the panels was eected with telescopic supporting
bars.

The fact that the concave roof creases and the convex wall creases form parallel

planes perpendicular to the oor, served as a guide and helped for the adjustment of the
panels.
Even though this was the carpenters rst experience with cross-laminated timber panels
and this type of structure the assembly got o perfectly well, was precise, and achieved
completion within ten days.

12.3.6. Gable faades.

The gable faades are oriented east-west.

Their form had

to answer to three criteria: procure a good natural lighting, guarantee a certain intimacy
and create contact with the natural environment. The timber framework is reminiscent
of a stained-glass window. The inside end wall is covered with corrugated polycarbonate
panels which have an excellent light transmission factor but slightly blur the outside view
because of their structure. A wind protection textile on the outside acts as a lter: during
the day it protects the inside of the chapel from the outside view, in the night the eect is
reversed and like a Chinese lantern, the chapel, signals its presence by a warm light.

Nails could have been used as connectors but, because the chapel is a temporary building, the possibility
to dismantle and rebuild it in an other place was foreseen. Screws were used to make the dismantling
easier.

268

12. THE CHAPEL OF ST.LOUP

longitudinal section

transversal section
(ECH.: 1/25)

(ECH.: 1/25)

Planche de protection
| avec goutte pendante

Arrtes latrales
Tles type bmf, plis
ep 3mm
largeur 300mm
en continue sur l'arrte
175 clous par ml

tanchit
panneau bois contrecoll 60mm
face exteriure fintion industrielle
Face interieure finition B

Arrtes en toiture V
Tles type bmf, plis
ep 3mm et 2 mm
largeur 240mm
en continue sur l'arrte
150 clous par ml

Arrtes latrales
Tles type bmf, plis
ep 3mm, largeur 300mm
en continue sur l'arrte
175 clous par ml

arrtes verticales ^
Tles type bmf, plis
ep 2 mm, largeur 320mm
en continue sur l'arrte
arrtes verticales V
150 clous par ml
Tles type bmf, plis
ep 2 mm et 3mm, largeur 240mm
en continue sur l'arrte
150 clous par ml

arrtes verticales ^
Tles type bmf, plis
ep 2 mm, largeur 320mm
en continue sur l'arrte
150 clous par ml

tanchit

panneau bois contrecoll 40mm


Face intrieure finition B
Face extrieure finition industrielle
Vis tous les 15cm
dia.8mm longueur 120mm

longrine bois quarri 160x120

Rampe d'accs:
panneau bois contrecoll 40mm
face suprieure finition B, stri
Face infrieure finition industrielle
sur longrines en bois equarri 80x120

plancher auvent
panneau bois contrecoll 40mm
face suprieure finition B, stri
Face infrieure finition industrielle
sur longrines en bois equarri
80x120

bo is e qu arri su rp lo t d e
b to n

panneau bois contrecoll 40mm


face intrieure finition B
Face extrieure finition industrielle
longrine bois equarri 80x120
sur plot de bton

longrine bois equarri 100x120 sur plotde bton


la longrine de bord suit la gomtrie des plis
renfort dans les points d'appuis longrine 80x120

tanchit
panneau bois contrecoll 60mm
face exteriure fintion industrielle
Face interieure finition B
Arrtes en toiture ^
Tles type bmf, plis
ep 2 m, largeur 320mm
en continue sur l'arrte
150 clous par ml

arrtes verticales V
Tles type bmf, plis
ep 2 mm et 3mm, largeur 240mm
en continue sur l'arrte
150 clous par ml

chassis bois 80x60 mm


tanchit l'air siclicone colle sur chassis
intrieur :panneau fibre de verre type neomat 3mm
extrieur: panneau trois pli dcoup
largeur 1950 mm hauteur variable

assemblage entre panneaux


rainure et languette rapporte
mdf

panneau bois contrecoll 40mm


face intriure finition B
Face extrieure finition industrielle

longrine bois equarri 80x120


sur plot de bton

Planche de protection
avec goutte pendante

Planche de protection
avec goutte pendante

Figure 12.3.3. construction of the chapel (photo: F.Hatt)

12.3. STRUCTURE AND CONSTRUCTION

Figure 12.3.4. Interior space and lateral facade (photos: F.Hatt)

269

270

12. THE CHAPEL OF ST.LOUP

12.4. Discussion
The project for the chapel of St.Loup shows a successful integration of architectural,
engineering, and production constraints in the design process. This conrms the interest
for folded plate structures with cross laminated timber panels and of the proposed design
method. The quality of the project is its ability to generate by a precise regulation of its
geometry relevant and synthetic answers to various constraints. It proposes

A religious space with high emotional, functional and symbolic character


An ecient structural solution
Integration of structure and space enclosure in a single layer
A simple answer to the rain water drainage
High acoustic and lighting quality

The materialization with cross-laminated timber panels resolves spatial enclosure, structure
and interior nish with a single element.
The design process was very fast and the design team and the client quickly agreed to
the proposed architectural and structural form. It is interesting to note that even though
we were searching for a close relationship to a traditional religious space, the form came out
of the inherent logic of the folding process: by making the space more narrow in direction of
the chancel it automatically grows vertically. The form of the space and the architectural
elements it evokes are proposed by the folding process itself and only have to be discovered
by the project designers in order to comprehend their signicance. It somehow reverses the
traditional design process

: it is not the intention that shapes the form, but the inherent

logic of the design method that suggests, during the design process, the intention.

The

relationship between intention and form gets blurred, the architect doesn't just imagine
the form but also discovers form and signicance by staying receptive to the implicit rules
of the design method he uses.
The quick fabrication and assembly of the timber panels showed the eciency of working with methods that generate geometries with discrete elements, and allow a rapid transition from design to construction. The joints to assemble the panels are simple and can
be executed by any carpenter.
The chapel is very appreciated by the deaconesses but also by a large public of experts
and laymen. Its somehow strange but familiar form, the simplicity of its construction, its
materiality, transmit an atmosphere and beauty beyond the traditional aesthetic categories.
Finally we have to mention the pioneering spirit of all participants to the project, but
particularly the one of the deaconesses. Their openness and enthusiasm was most decisive
to the realization of the chapel.

or at least what most of the architects think it is.

12.4. DISCUSSION

Figure 12.4.1. The entry porch and the west facade (photos: F.Hatt)

271

272

12. THE CHAPEL OF ST.LOUP

Credits
Client:

Communaut des dicaconesses de St.Loup

Architecture:

Groupement d'architectes: Localarchitecture, Bureau d'architecture Danilo Mondada

Shel, Hani Buri, Yves Weinand, Architecture, Engineering and Production Design

Engineering:

Shel, Hani Buri, Yves Weinand, Architecture, Engineering and Production Design

Funding:

Federal Oce for the Environment FOEN

CREDITS

Figure 12.4.2. The Chinese lantern, light reection on walls and roof

panels (photos: F.Hatt)

273

CURRICULUM VITAE

275

Curriculum vitae
Hani Buri
Born in Bern, Switzerland, 27 Mai 1963
Married, two children

Education
2005-2009

Doctoral school, EPFL, Lausanne

2004

Project coordination for sustainable building, HES, Geneva

1991

Master of architecture, EPFL, Lausanne

1984

Matura, Freies Gymnasium, Bern

Professional experience
Shel , Hani Buri, Yves Weinand, Architecture, Engineering and Production Design

since 2008 Co-founder and partner of

since 2005 Scientic collaborator, laboratory for timber constructions, IBOIS, EPFL
1993-2005

1991-1993

BMV architectes, Hani Buri, Olivier Morand, Nicolas Vaucher, architectes EPFL
Co-founder and partner of

Independent architect

Teaching
since 2006 Course instructor, timber construction course for architects and engineers,
EPFL
since 2006 Assistant, Atelier Weinand, EPFL
since 1995 Visiting critic, and lectures in dierent architecture classes, EPFL, EPFZ,
ESBA, IAUG
1994-1998

Assistant, Professor P. von Meiss, EPFL

1993

Assistant, visiting professors D. Marques and B. Zurkirchen, EPFL

1993

Assistant, visiting professor E. Souto de Moura, EPFL

1992

Assistant, visiting professor M. Dominguez, EPFL

Miscellaneous
languages

German: native language


French: spoken and written
English: spoken and written

Fdration des Architectes Suisse, FAS, member of the committee, section Geneva
Fdration des associations d'architectes et d'ingnieurs de genve, fai, member of the
committee
Schweizerische Arbeitsgmeinschaft fr Holzforschung, SAH, member of the committee

S-ar putea să vă placă și