This dissertation sets out to investigate the developability of freeform surfaces, including double curved surfaces, employing kerf bending as a cornerstone of the process. The need for such research stems from the rapid advancements made in the field of computer aided design and manufacturing, or CAD and CAM respectively. Allowing designers and engineers to envision and produce ideas with ever-increasing complexity. To meet this new level of complexity, research into new and advanced production methods must be done. This thesis is an effort to include the traditional technique of kerf bending within the advancements of today’s production methods.

The research starts with the creation of a parametrical model capable of generating a support and construction method for any freeform surface, within Rhinoceros 3D (and its extention Grasshopper). The assumptions and ideas used in the first version of the model are assessed through physical experiments. The experiments include material testing as well as the construction of various mock-ups. These tests were instrumental in gathering information to improve the physical behaviour of the model to increase its viability.

The research concludes with a 1:1 mock-up of a design generated within the final version of the model, SCELL. The final version incorporates all results and findings of the experiments as well as some implemented optimisations. Using kerf bending to define the smallest cells of the shell, the overall shape of the design is closely approximated.