In mechanical engineering and architecture, structural elements with low material consumption and high load-bearing capabilities are essential for light-weight and even self-supporting constructions. This paper deals with so called point-folding elements - non-planar, pyramidal panels, usually formed from thin metal sheets, which exploit the increased structural capabilities emerging from folds or creases. Given a triangulated free-form surface, a corresponding point-folding structure is a collection of pyramidal elements basing on the triangles. User-specified or material-induced geometric constraints often imply that each individual folding element has a different shape, leading to immense fabrication costs. We present a rationalization method for such structures which respects the prescribed aesthetic and production constraints and ?nds a minimal set of molds for the production process, leading to drastically reduced costs. For each base triangle we compute and parametrize the range of feasible folding elements that satisfy the given constraints within the allowed tolerances. Then we pose the rationalization task as a geometric intersection problem, which we solve so as to maximize the re-use of mold dies. Major challenges arise from the high precision requirements and the non-trivial parametrization of the search space. We evaluate our method on a number of practical examples where we achieve rationalization gains of more than 90%.

Several theoretical and practical geometry applications are based on polygon meshes with planar faces. The planar panelization of freeform surfaces is a prominent example from the field of architectural geometry. One approach to obtain a certain kind of such meshes is by intersection of suitably distributed tangent planes. Unfortunately, this simple tangent plane intersection (TPI) idea is limited to the generation of hex-dominant meshes: as vertices are in general defined by three intersecting planes, the resulting meshes are basically duals of triangle meshes.

The explicit computation of intersection points furthermore requires dedicated handling of special cases and degenerate constellations to achieve robustness on freeform surfaces. Another limitation is the small number of degrees of freedom for incorporating design parameters.

Using a variational re-formulation, we equip the concept of TPI with additional degrees of freedom and present a robust, unified approach for creating polygonal structures with planar faces that is readily able to integrate various objectives and constraints needed in different applications scenarios. We exemplarily demonstrate the abilities of our approach on three common problems in geometry processing.