Curve Crease Folding (CCF) is an emerging forming process in which flat sheet metal is folded along curved paths to produce stiff three-dimensional geometries from a single sheet. While industrial design workflows for CCF rely on digital simulation, the relationship between simulated and physical outcomes has not been systematically characterised, limiting the reliability of early-stage design decisions.

This thesis develops and applies a quantitative measurement and analysis workflow for CCF. A full factorial experiment was conducted at STILFOLD, forming 30 stainless steel 304 sheets across three crease geometries (A, B, and C) and two sheet thicknesses (1.0 mm and 1.5 mm), with five replicates per combination. Each sheet was captured using a structured light 3D scanner and processed through an automated Python pipeline combining landmark-based Kabsch alignment, RMS deviation analysis, and Gaussian curvature computation. Two-way ANOVA was used to assess the effects of geometry and thickness on four response variables. Sheet thickness was the dominant factor governing geometric deviation (F = 751, p < 0.001). At 1.0 mm, RMS deviation from the simulation ranged from 1.47 to 1.75 mm across all three geometries, with no statistically significant differences between them. At 1.5 mm, RMS deviation rose to 4.43 mm for geometry A and 5.23 mm for geometry B, while geometry C remained at 1.52 mm. The geometry-by-thickness interaction was statistically significant (F = 231.5, p < 0.001). Deviations were concentrated near the crease across all groups, consistent with springback-driven deformation. Gaussian curvature analysis showed that dimensional accuracy and local surface developability capture complementary aspects of forming quality.

At 1.0 mm, all three geometries produced consistent, predictable behaviour suitable for simulation-based design. At 1.5 mm, only geometry C maintained comparable accuracy. The findings were applied to the design of ARC, a wall-mounted lighting fixture formed from a single 1.0 mm stainless steel sheet, demonstrating how quantified forming behaviour can directly inform geometry and material selection in product development.