Developable Product Forms

Developable Surface

In mathematics, a developable surface is a surface that can be flattened onto a plane without distortion

Many developable surfaces can be visualised as the surface formed by moving a straight line in space

Developable surfaces that can be realized in 3D space are cylinders, cones, planes

Spheres are not developable as they cannot be unrolled into a plane

All developable surfaces are ruled surfaces Not all ruled surfaces are developable surface,

hyperboloids are examples of ruled surfaces that are not developable

Developable Product Forms

Straight ruled surfaces appears on many products formed by folding and bending sheet materials

Skilful combination of ruled surfaces can make a mathematically simple developable surface looks as dynamic as very complex surface

By introducing free-form curves and varying the matching endpoints, designers can introduce dynamism to the product form

Sheet Metal Components and Enclosures

Sheet Metal Consoles

Bendable Interior ObjectsEasy.Storage for B-LINE by Matthias Demacker

Sheet As Structures

Lightlight table lamp by stauffacherbenz

Sheet As Structures

origami.series for van esch by Matthias Demacker

Come back by Velopa

Sheet As Structures

Vertigo side table by AquilialbergBourgogne by Mikael Ling

Di Classe FULGURO's reLeaf

Creep tables and shelves by Susan Bradley's

Light as a feather'Alle cinque' Trays by Serafino Zani

Sheet As Decoration

Driade 100 PIAZZE by Fabio Novembre

Flexible Sheet Materials

Salad Set by Karichdesign'Flat' Travel tray by Marco Susani, Mario Trimarchi

Kombinationsbestick by Kristin Granath

Tote by conphorm

Flexible Sheet Materials

Opus series by Lamina Design

Adapted from: http://www.laminadesign.com

Paper Sculpture by Peter Callesen

Impenetrable Castle by Peter Callesen On The Other Side by Peter Callesen

Sheet Metal Forming

Bending

Bending is a common manufacturing method to process sheet metal. It is usually done on a bend press (or break press), but also swing-bending-machines are used. Typical products that are made like this are electrical enclosures

Adapted from: http://en.wikipedia.org/wiki/Image:Biegeanimation_3D.gif

Rolling

Rolling is a fabricating process in which the metal, plastic, paper, glass, etc. is passed through a pair of rolls

There are two types of rolling process, flat and profile rolling

In flat rolling the final shape of the product is either classed as sheet (typically thickness less than 3 mm, also called "strip") or plate (typically thickness more than 3 mm)

In profile rolling, the final product may be a round rod or other shaped bar such as a structural section (beam, channel, joist etc)

Heavy plate tends to be formed using a press process, and is termed forming, rather than rolling

Roll Forming

Roll forming is a continuous bending operation in which a long strip of metal is passed through consecutive sets of rolls, or stands, each performing only an incremental part of the bend, until the desired cross-section profile is obtained

Ideal for producing parts with long lengths or in large quantities

A variety of cross-section profiles can be produced, but each profile requires a carefully crafted set of roll tools

Activity – Lamp-shade Design

Design a new lamp-shade for IKEA DINGE, the design should be manufactured by cutting and folding PP plastic sheet

Test your design on paper

Cut your final design on card

Adapted from: IKEA DINGE