Total noob here approaching with a passion project base on origami cranes. I'm developing a roughly 24-inch-wingspan origami-style aluminum crane sculpture and would appreciate a practical sheet-metal design review before ordering parts.
I live in Costa Rica. My original plan was to order cut and bent parts from SendCutSend or OSH Cut, ship to a US freight forwarder, then assemble here. Replacement parts would mean another international shipment, so I'd like to identify avoidable problems before cutting.
The attached CAD shows the current design candidate. It has not been physically built or tested. The photorealistic image is an AI visualization of the intended appearance, not a photograph of a working prototype. The design was developed with substantial AI assistance; I'm seeking experienced human review rather than treating the computer checks as validation.
CURRENT CONSTRUCTION
- Approximately 24-inch (610 mm) wingspan.
- 5052-H32 aluminum: 0.063-inch (1.60 mm) wings/body/brackets and 0.125-inch (3.18 mm) internal frame and flat neck/tail.
- Two tapered wings, each with a longitudinal crease. The neck and tail currently remain flat silhouettes.
- Seven internal frame pieces supporting a faceted body, wings, neck and tail.
- Lower body sides have inward bent flanges; a removable belly bolts to clinch nuts.
- 33 sheet-metal pieces total, including 18 separate brackets/clips; 44 #6-32 screws.
- Visible fasteners are acceptable. I'd prefer to avoid glue and welding for the proposed kit.
- A proposed 3/8-inch display rod enters through the underside. Mounting capacity and balance have not been physically validated.
WHAT HAS BEEN CHECKED
The digital model has been checked for nominal part/hardware interference and a proposed assembly sequence. Those checks use idealized geometry. Actual bend variation, tolerance accumulation, wrench/driver access, stiffness and physical assembly remain unverified. Fabrication is on hold.
QUESTIONS
1. Is the internal frame justified at this size, or would you use a folded, bolted shell with fewer brackets? What would you simplify first while preserving the silhouette?
2. What are the most likely failure points in manufacturing or assembly: bend accuracy, holes near bends, fastener access, tolerance accumulation, wing flex, or something else?
3. What is the smallest useful physical test before committing to the whole kit: representative joints, one wing/root assembly, or a complete first article?
4. Does anyone know an individual or small shop that accepts a paid review or one-off prototype assembly? A Costa Rica option would be especially helpful; US fabrication/assembly before forwarding is another possibility.
I'm happy to provide dimensioned joint details and the assembly model for a focused review. I'm looking for specific changes and a realistic validation process before spending money on the final parts.