At first we did design of aluminium sphere as constructive assembly of joints and folding. Design strategy was based on using the 0.3 mm thick aluminium and the EndCut Mill tool 0.3 mm in diameter. In this case one mill cut matches thickness of material, making joints possible.

As we starded to mill our material, we realized that parts designed for joints are too thin and fragile to be succesfull. Because of that we focused only on the folding of aluminium. This was done by engraving the folding lines.

We also had problems with melting of aluminum during the milling process. But we were able to cut of the melted part manually.