Trying to find the proper workflow for flattening curved surfaces

[Vintagetunes]

Hi y'all!

I had someone ask me to design some wavy light channels for a ceiling, and I'm trying to figure out the best way to model them in a way that they could be flattened, and cut on a CNC router.  I drew a super quick representation of what I'm trying to do, but I haven't been able to find a method to flatten the three pieces correctly.

Any ideas would be so appreciated!  It's turned into a bit of a brain teaser for me

Thank y'all! - DMc

[TrippyLighting]

You cannot flatten infinitely thin surfaces in Fusion, unfortunately.

You can add a little straight section to each of the vertical surfaces, thicken them, convert them into sheet metal bodies and then create a flat pattern, that you can export as a DXF, for example.

The swept bottom surface cannot be flattend that way, as it is a non-developable surface.

However, one caveat, you should NEVER use a patch for a 4-sided surface, That should be a loft!

In this case the wave should be an extrusion that should be trimmed, or intersected with an extrusion.

I've attached a sample file to "explain" what I mean.

[Warmingup1953]

Just a thought bubble but I'd probably keep the sheetmetal rules in mind and simply model the plywood faces as sheet metal bodies...All three here Flat pattern and unfold.

EDIT: Oops the underside errors when Flat patterning but as I said it's just a thought bubble!

Edit 2:  A bit of fudging on the underside yield a flattened body:

[MichaelT_123]

How ya goin' Mr VintageTunes,

Consider looking at:

• https://forums.autodesk.com/t5/fusion-design-validate-document/flat-pattern-for-twisted-sheet-metal/... - look at "invariant" phrase and apply the concept to one of the edges of your design
• https://forums.autodesk.com/t5/fusion-design-validate-document/auger-flight-sections-into-flat-patte...
• https://forums.autodesk.com/t5/fusion-design-validate-document/flattening-surface/m-p/12059033  - I reckon, this one will be of no use in your case ...  so treat it as a CAD'tucker.  

R'go Mate

MichaelT

[MichaelT_123]

Hi Mr VintageTunes, 

Your double-wave phenomena object looked so interesting … that I decided to flatten it to see it when it was younger (older?). In order to raise the excitement of the process, I punched a dozen or so holes in the original you supplied. The flattened face and hole cutouts (slightly shifted for visibility) are contained in a separate component. Look at the content of its description label.

(Comp:Body)=(Squid_with_holes:Body3)Base Face Area = 8.30952 cm² Flat Face Area = 8.30952 cm² CutOut_2 Area  = 0.0530946 cm² CutOut_3 Area  = 0.052971 cm² CutOut_4 Area  = 0.0515522 cm² CutOut_5 Area  = 0.0513411 cm² CutOut_6 Area  = 0.0512957 cm² CutOut_7 Area  = 0.0512696 cm² CutOut_8 Area  = 0.0511721 cm² CutOut_9 Area  = 0.0508575 cm² CutOut_10 Area  = 0.0507276 cm² CutOut_11 Area  = 0.0506794 cm² CutOut_12 Area  = 0.0506384 cm² Output surface flatness:  average: 0  maxDev: 0  threshold: 1e-05 (Histogram_of_ΔP)(min=-0.00944898,max=-0.00922145) (Histogram_of_ΔA)(min=-0.000876243,max=-0.000785618) (Histogram_of_ΔD)(min=7.91364e-07,max=8.08374e-05)

Your modified file, together with some visuals, is attached.

By anticipating the question: Where are the histogram objects in the f3d file? … unfortunately, your Fusion could not render them.

Here is a short explanation of some histogram symbols:

• ΔA – flattened surface local relative area size error
• ΔP – flattened surface local relative perimeter length error
• ΔD – flattened surface local maximum length distortion along UV axes

Attached files:

Flatten_Wave_2D.f3d                 F3D               (6.2MB)  https://a360.co/3QfEPdd

Flatten_Wave_2D.png               HD_mono     (0.2MB)  https://a360.co/3QdjAJ3

Flatten_Wave_2D_mono.png    4K_mono    (0.3MB)  https://a360.co/3QaZDCS

Flatten_Wave_2D_stereo.png   4K_stereo   (1.4MB)  https://a360.co/3W6YH5V

Flatten_Wave_2D_mono.mp4   4K_mono    (3.1MB)  https://a360.co/3vZeJ7u

Flatten_Wave_2D_arcd.mp4     4K_stereo   (5.5MB)  https://a360.co/3xM3BeL

To be viewed on 4K media devices (monitors, UHD TVs, projectors...) of reasonable performance. For the best experience, use stand-alone media applications (WMP, VLC) and the native resolution 3840x2160 - full screen. The '_arcd' files require an anaglyph red/cyan glasses, while '_al' is for active shutter glasses 3D hardware (~30 deg viewing angle is recommended). Download the files over a network, where the cost of doing so is not a concern. The files are to be used for private, non-commercial purposes only.

Regards

MichaelT