Abstract This paper introduces an algorithmic method for designing and fabricating soft curved-folded surfaces using minimally stretchable thick panels, validated via the production of a free-form sculpture in fiber cement board. The proposed digital workflow combines crease-aware mesh generation with elastic simulation in Rhinoceros and Grasshopper. The study demonstrates how carefully calibrated constraints and real-time user adjustments enable the shaping of a complex, self-supporting form while minimizing material stretching and ensuring partial developability. A tailored manufacturing process, involving a digitally modeled and 3D-printed mold, facilitates the shaping of fiber cement with soft folds. Although tested on a 160 cm high sculpture, the method is broadly applicable to other foldable sheet goods with similar properties, offering the potential for both architectural and manufacturing applications.
Koschitz et al. (2026) studied this question.