Parametric Design Investigation and Mechanical Performance of Laser-Cut Kerf Bending in Plywood Sheets

Kerf bending, a technique for curving material through repeated cuts, has evolved into a powerful tool in design and construction. Following experimental methodology, aiming at the design and construction of flexible and functional surfaces at real scale, this paper presents a creative Kerf Bending technique using a laser-cutting CNC machine. This research reviews the relevant techniques related to geometries, bending methods, and parameters that affect the behaviour of the material, wood. A systematic experimental process was undertaken, involving several birch plywood test specimens, on which different patterns were cut. The mechanical properties of the samples are tested to accurately record the performance under deformation, elasticity, and flexibility of each specimen. Comparative analysis showed that kerf geometry is the primary factor influencing the bending performance of plywood panels, having a greater impact than thickness or material removal percentage. Thinner specimens consistently demonstrated improved curvature capacity and higher load resistance, indicating more efficient stress distribution during deformation. Flexibility and strength were not directly proportional to the amount of removed material; instead, geometrically optimised layouts achieved favourable deformation while retaining mechanical integrity, whereas excessive removal reduced structural performance. The findings confirm that carefully designed kerf patterns can balance flexibility, strength, and aesthetic quality, supporting their use in structurally functional bent plywood components.