Arbitrarily curved support structure

A method of producing a carrier structure which extends in a three-dimensional geometry of any desired curvature and which comprises at least one first and one second flat piece of material, wherein the geometry has curvatures in three mutually orthogonal directions, the method comprising:

• A. providing a desired geometry in digital form,
• B. approximating the desired geometry by determining a plurality of polygonal cross sections along an extent of the geometry and connecting the side lines of mutually successive polygonal cross-sections by loft surfaces,
• C. dividing the geometry into at least one first and one second part which run along at least one part of the extent of the geometry,
• D. specifying at least one clearance area of adjoining loft surfaces in the area of each polygonal cross section,
• E. specifying a plurality of junctions arranged at the at least one first and one second part along the extent of the at least one first and one second part in order to later connect the at least one first and one second part,
• F. specifying bevel edges extending between the polygonal cross sections,
• G. unwinding the at least one first and one second part which are provided with the clearance areas and junctions and producing a cut contour in relation to the at least one first and one second part, wherein one of the curvatures located in three mutually orthogonal directions is represented in the cut contours,
• H. cutting at least one first and one second flat piece of material in accordance with the cut contours in relation to the at least one first and one second part,
• I. beveling the cut at least one first and one second flat pieces of material along the bevel edges resulting in at least one beveled first piece material and at least one beveled second piece of material, and
• J. connecting the at least one beveled first piece of material and the at least one beveled second piece of material along the junctions, wherein a rotating and/or twisting procedure of mutually adjoining areas of the at least one beveled first piece of material and the at least one beveled second piece of material permitted by the clearance areas is effected to represent the remaining two of the curvatures present in three mutually orthogonal directions and wherein the rotated and/or twisted at least one beveled first and one beveled second piece of material are fixed by the connecting step.