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

Kerf bending, achieved through precisely patterned cuts, enables the transformation of rigid plywood into flexible, adaptive surfaces for advanced design and ergonomic applications. This preliminary, exploratory study systematically investigates 56 laser-cut kerf geometries—spanning both traditional and novel parametric patterns—in birch plywood sheets of two thicknesses. Mechanical performance was evaluated via standardised testing, with statistical analyses (including Weibull and coefficient of variation) employed to interpret the pronounced variability observed in maximum load (Fmax) values, even among geometrically similar patterns. Due to the limitation of single-specimen destructive testing per pattern, the results should be understood as indicative trends within this experimental set, not as definitive rankings. Observed results suggest that kerf geometry and arrangement—rather than thickness or gross material removal—are the primary determinants of flexibility and strength. Notably, specific parametric and meander-type patterns demonstrated promising balances of deformation capacity and mechanical reliability within this limited dataset. The inherent limitations of experimental replication and natural material heterogeneity are explicitly acknowledged, and the findings are intended as a foundation for future, more statistically robust investigations. This work provides a comparative framework and initial design guidance for kerf-based plywood structures and identifies key priorities for further research in replication, material selection, and real-world applications.