Metal Blossom: Laser Forming Complex and Freeform Metal Structures Imitating Flower Blooming

For centuries, human civilizations devised metal forming techniques to make tools and items; yet, customized metal forming remains costly and intricate. Laser-forming origami} (lasergami) is a metal forming process where a laser beam cuts and folds a planar metal sheet to form a three-dimensional (3D) shape. Designing foldable structures formable by lasers, however, has long been a trial-and-error practice that requires significant mental effort and hinders the possibility of creating practical structures. This work demonstrates for the first time that lasergami can form a freeform set of metallic structures previously believed to have been impossible to be laser-formed. This technological breakthrough is enabled by new computational origami methods that imitate flower blooming and optimize laser folding instructions. Combined with new ideas that address laser line of sight and minimize fabrication energy, we report a low-cost manufacturing framework that can be readily adopted by hobbyists and professionals alike.