Transforming 3D Models to DXF for Manufacturing

We are 4A Metal, a French metal fabrication company equipped with industrial laser cutting and sheet-metal machinery.

We manufacture low-poly metal sculptures from 3D models.

We already have the 3D OBJ models. We are NOT looking for someone to create the 3D models or make renders.

We are looking for a freelancer who can transform our existing low-poly OBJ models into production-ready unfolded DXF files for sheet-metal manufacturing.

The sculptures are laser-cut from approximately 1.5 mm steel, manually folded into shape and then welded together.

This is therefore not ordinary papercraft. The unfolded parts must be designed specifically for real metal fabrication.

What we need

The freelancer must:

* Import and analyse the supplied OBJ model.
* Determine an intelligent division of the sculpture into manufacturable metal parts.
* Keep several connected facets together whenever practical, instead of making every triangle a separate part.
* Decide which edges should remain folds and which edges should become cut/separation edges between parts.
* Avoid pieces containing an unreasonable number of folds or folds that would be physically difficult/impossible to perform by hand.
* Unfold every resulting metal part accurately into 2D.
* Number all parts and matching assembly edges.
* Clearly distinguish mountain and valley folds / folding direction.
* Indicate the required fold angle whenever possible.
* Prepare the fold lines for our laser-cutting process.
* Deliver clean DXF files ready for our laser software.

Very important – Fold-line design

Our parts are manually folded after laser cutting.

We therefore want the internal fold lines designed so that they can be processed directly by our laser.

The preferred principle is a fold line composed of:

engraving / marking – small cut or relief – engraving / marking

along the folding axis.

The purpose is to:

* clearly identify the exact folding line;
* indicate the folding direction;
* facilitate manual bending;
* reduce the force required to create the fold;
* maintain enough material between the facets so that they remain connected as one physical part.

The exact geometry of this system can be developed together and standardized for all future sculptures.

The freelancer therefore needs to understand that the DXF is not simply a visual unfolded pattern. It must actually work in sheet metal.

Production philosophy

We do NOT want:

one separate piece for every triangle
automatic unfolding with huge impractical islands
hundreds of unnecessary welds
fold patterns that are impossible to reproduce manually
a PDF intended only for paper/cardboard

We DO want:

✓ intelligent groups of connected facets
✓ practical manual folding
✓ fewer physical pieces where possible
✓ logical weld seams
✓ clearly identified fold directions and angles
✓ numbered assembly edges
✓ clean laser-ready DXF files
✓ repeatable manufacturing logic

First paid test

The first project will be a paid test using one existing low-poly OBJ model.

If the manufacturing files are good, we have many additional sculptures to develop and are looking for a long-term collaboration.

Please apply only if you have experience with at least one of the following:

Pepakura / Blender unfolding / papercraft development / low-poly mesh preparation / sheet-metal unfolding / laser-cut fabrication.

When applying, please send us examples of previous unfolded models or comparable work.