Abstract: Apparatus and methods for forming three dimensional structures from a sheet of material of a desired medium are described. Examples described include an apparatus for folding a sheet of material to create a folded structure, the apparatus having a first and second array of creasing elements, and at least one actuator for causing relative movement of the first and second array of creasing elements from a first position to a second position.

Abstract: A three-dimensional support structure is provided and includes a single sheet of material that is folded into a repeating pattern of cells. Each of the cells is formed by first and second spaced-apart endwalls and first and second sloped sidewalls spanning between the endwalls. Each endwall comprises two plies of material while each sidewall comprises a single ply of material. The first and second sidewalls are adjoined at a folded edge. The cells are aligned such that the first endwall of one cell from the repeating pattern abuts the second endwall of an adjacent cell of the repeating pattern to form a four-ply wall of the material. A first liner may be attached to a first side of the folded material and a second liner may be attached to a second side of the folded material.

Abstract: A three-dimensional support structure is provided and includes a single sheet of material that is folded into a repeating pattern of cells. Each of the cells is formed by first and second spaced-apart endwalls and first and second sloped sidewalls spanning between the endwalls. Each endwall comprises two plies of material while each sidewall comprises a single ply of material. The first and second sidewalls are adjoined at a folded edge. The cells are aligned such that the first endwall of one cell from the repeating pattern abuts the second endwall of an adjacent cell of the repeating pattern to form a four-ply wall of the material. A first liner may be attached to a first side of the folded material and a second liner may be attached to a second side of the folded material.

Abstract: A three-dimensional support structure is provided and includes a single sheet of material that is folded into a repeating pattern of cells. Each of the cells is formed by first and second spaced-apart endwalls and first and second sloped sidewalls spanning between the endwalls. Each endwall comprises two plies of material while each sidewall comprises a single ply of material. The first and second sidewalls are adjoined at a folded edge. The cells are aligned such that the first endwall of one cell from the repeating pattern abuts the second endwall of an adjacent cell of the repeating pattern to form a four-ply wall of the material. A first liner may be attached to a first side of the folded material and a second liner may be attached to a second side of the folded material.

Abstract: A three-dimensional support structure is provided and includes a single sheet of material that is folded into a repeating pattern of cells. Each of the cells is formed by first and second spaced-apart endwalls and first and second sloped sidewalls spanning between the endwalls. Each endwall comprises two plies of material while each sidewall comprises a single ply of material. The first and second sidewalls are adjoined at a folded edge. The cells are aligned such that the first endwall of one cell from the repeating pattern abuts the second endwall of an adjacent cell of the repeating pattern to form a four-ply wall of the material. A first liner may be attached to a first side of the folded material and a second liner may be attached to a second side of the folded material.