Complex laser folding and fabrication

A method of cutting and folding a substrate that defines a plane with a focused laser beam, directed from above the substrate, to form a three-dimensional (3D) element with features in 3-dimensions, the method comprising:

• (A) providing:
• a first reel configured for dispensing the substrate;
• a second reel configured for receiving the substrate;
• a guide element for providing a flat area of the substrate between the first and second reels;
• and
• the focused laser beam configured to strike the substrate in the flat area;
• (B) executing from above laser cuts to the substrate, which is initially unpatterned and planar, so as to provide one or more releasable segments;
• and
• (C) executing one or more folds to form the 3D element by preforming one or more of:
• (i) from above one or more laser-executed upward folds to bend at least one releasable segment of the one or more releasable segments;
• or
• (ii) from above one or more laser-executed downward folds to bend at least one releasable segment of the one or more releasable segments,
• wherein the cuts and folds are structured so that precursors to the 3D element remain attached to the substrate while sufficient cuts and folds are made to form the 3D element, and wherein the substrate is immobile during said steps (B) through (C), or is only moved in the plane of the substrate pursuant to the operation of the reels;
• and
• wherein the method further comprises:
• cutting and folding a portion of the substrate to form a reflector;
• and
• re-directing the focused laser beam using the reflector to cut, etch or fold at least one of the one or more releasable segments that would otherwise be inaccessible to the focused laser beam from above.