A new type of structural form has been developed that enables ultra-light sandwich constructions at architectural scales. Deemed folded shell structures, they are created by attaching faceted inner and/or outer face sheets to a folded plate core pattern. The faceted faces provide two major benefits over traditional curved-face sandwich construction: they enable strong, continuous edge connections between core and face layers; and they allow unbent, rigid sheet materials such as metals and composites to be assembled into complex curved geometries. Full details of folded shell design and construction techniques are given in a submitted patent application to be published next year.
Click on the below links to see animated examples of folded shell structures.