4 Arup Airbag Particle Course Folding 2015 v1.3 PDF

Airbag Folding in Primer
Revision 1.3 2015

© Arup 2015 All Rights Reserved
Do Not Copy Without Permission
Contents
• Introduction
– Information needed to fold an airbag
– Measuring the real airbag
– Deciding the best folding approach
• Introduction to Primer’s airbag folding tools
– Airbag Folder Types
– Definitions Used in Primer’s Airbag Folding
– Important Information
– Displaying the REFERENCE GEOMETRY
– Which Folder Should I Use?
– General Folding Guidelines
• Two examples of side airbag folding
– Zig-zag (or accordion) fold
– Roll (or spiral) fold
– Fitting the inflator
– Fitting inside the case
– Mesh-independent folding
• Advanced techniques (driver’s airbag example)
– Folding for a realistic shape and constant element size
– Folding half a bag then using reflect-copy
– Fitting the inflator
• Mesh-independent folding
• 3D airbag folding

Rev. 1.3 2015 © 2015 Arup All rights reserved. 2
Introduction
This is a guide to folding 2D airbags using Primer.
This is one part of a larger training course covering the

Corpuscular Particle Method (CPM) or AIRBAG PARTICLE in
LS-DYNA.
The folding patterns shown in these slides are typical but made up.
They should not be considered accurate or indicative of any particular
airbag.
Note, most of this course deals with 2D airbags. 3D folding is mentioned at the end.

Introduction
• There are basically two ways to fold an airbag model using current
technology:
1. Using the geometric folding capabilities in a pre-processor such as Primer
2. Using a non-linear solver like LS-DYNA to deform the mesh into a folded shape
• Both methods have their advantages and disadvantages, and like any tool
the user must decide the best one for the job: based on time available,
model complexity, required accuracy and of course the skill of the user.
• Recently the solver-based approach has rapidly gained popularity and a
powerful, Primer-based software product called JFOLD is available for
folding in LS-DYNA.
• However in many cases, a geometric based folder like Primer is still the
best tool for the job:
– For a simple fold pattern, Primer will produce an accurate folded airbag model in a
fraction of the time needed for a solver-based approach, provided the user has
enough knowledge of how to use the software.
• Actually, we usually find that a combination of Primer and LS-DYNA often
gives the best and quickest result, and these methods are presented in the
course.
• The objective of this training module is therefore to give users enough
knowledge to fold simple models in Primer, so that they can decide where
and when Primer is the best tool for their airbag folding job.

Information Needed to Fold an Airbag
• Items marked * are essential
• * Real airbags: preferably two newly folded and two post-test.
– New (not tested) folded airbags are needed to obtain accurate information for folding
– At least one new airbag should be attached to it’s jacket and module case and contain the
inflator (post-test or deactivated)
– We recommend keeping one new airbag always correctly folded to use as a reference
throughout the project
– The post-test airbags are useful to inspect for stretch/fraying/burning and can be cut open to
measure internal chambers, tethers, inflator location, etc.
• CAD line data of airbag fabric in flat unfolded condition
– All details should be included in the data: internal tethers, bolt and vent hole locations etc.
– CAD dimensions should be as accurate as possible (but seldom are)
– If the airbag is 3-D type then usually the supplier provides designs of the pre-sewed flat
fabric pieces and a general arrangement drawing of the idealised 3D shape. We strongly
recommend obtaining scanned 3-D surface data of the inflated condition as well.
• Folding instructions: e.g. sketches (including measurements) showing how each
fold is made.
– If possible, watch the manufacturer fold the airbag, live or by video.
– Find out what folds are important elements of the design – these may be small but influence
how the bag deploys.
• Design/specification volume (approximate is ok)
• Usually the inflator is included in the final airbag model so this mesh (or that of a
similar shape) is required during the folding process

Measuring the Real Airbag
• First we recommend carefully studying the real airbag to understand the
true design, dimensions and folding pattern.
• CAD or printed sketches are a useful reference but the real airbag can
be quite different
Don’t use the dimensions from the folding pattern – they are usually not accurate
• Take accurate measurements from a new real airbag for meshing
Folding schematics like these are rarely

the same dimensions as the real airbag
True size 
Hong, S., Jung, H., Cho, B., Kim, I. Hyundai MOBIS, Korea, Paper Number 07-0274, “A STUDY ON INVISIBLE
KNEE AIRBAG CUSHION FOLDING DESIGN USING DOE (DESIGN OF EXPERIMENTAL) METHOD”

Measuring the Real Airbag Make notes to record fold types
Draw lines on fold creases
• Photograph each step (for reference and your report)

Use bolt hole as datum
• Starting with a “factory-condition” folded airbag
• Measure the overall dimensions of the wrapped package Stretch the fabric to get
accurate measurement
• Measure the location of the bolts relative to the overall dimensions
• Remove the wrapper carefully by pulling it over the bolts – avoid breaking the fabric tabs
• With a marker pen draw lines along all visible fold edges
• Gradually open each fold, if many write the number on the area of fabric exposed and trace over
the fold lines with a marker pen. Draw “peak” and “valley” fold lines in different colours or line styles.
• Once fully open, measure the exact size and shape of the unfolded condition. This can be difficult if
the shape is mostly curved. Use the bolt holes as a straight edge reference line and mark out a grid
on the fabric to obtain the true overall shape. Most airbags do not open perfectly flat and will
require pulling taught to obtain the correct dimensions.

Deciding the Folding Approach
Once accurate dimensions are established, a flat (2-D) model

should be meshed
• If all the folds are orthogonal (at 00 and 900 to each other) then
we recommend creating the initial mesh by hand.
• This can then be folded using Primer’s Regular Folder
• If the fold pattern is not orthogonal (e.g. a tuck fold at an angle)

then we recommend using Primer’s Mesh Independent Folder
• In this case the initial model does not have to have mesh lines
in the same places as the fold lines
• These are explained in more detail later.

Quick Introduction to Airbag Folding in Primer
Airbag Folder Types
There are currently 3 types of folder available in Primer:
1. Regular Folder
- Folds airbag using mesh lines already in the
model
Create flat mesh - Stores origami data as node sets and
of correct shape transformations
with mesh lines 9 fold types available
along fold lines Scrunch fold has limited capability
Create 3-D mesh
2. Special Folder
- Auto-creates 2 types of “radial-compression”
folds (star or circle) for circular airbag
Create flat mesh 3. Mesh Independent (“MI”) Folder

of correct shape - Splits mesh at required fold line and re-
- fold lines are meshes in TRIAS at every step
not needed - Stores origami data as geometric areas
and transformations
5 fold types available
Auto-create circle also available

Airbag Folder Types
Regular Mesh Independent
Fold Types Types
Regular Folder
Special
Folder
These folds cannot be done with the

Mesh Independent Folder mesh-independent folder because
NODES are re-created every step

Definitions Used in Primer’s Airbag Folding
• Primer uses the following definitions to describe airbag data used in folding:
• “ORIGAMI” = the overall set of data containing everything required to define the
geometrical extent of an airbag, and its associated folding operations:
– The origami label (which must be unique within a model) and title
– A list of elements and nodes (as sets) which comprise the bag; (OR a list of geometrical areas in
the case of MESH-INDEPENDENT folding)
– A list of FOLDs
– A local coordinate system
– A list of ORIENTs
• “FOLD” = a generalised term for the many fold types available (e.g. rolling a bag up is
described in Primer as a “spiral fold”). Each FOLD definition contains:
– The fold number and type (thin, thick, roll, tuck, ...)
– An optional coordinate system
– Geometrical data (location, direction, angle, thickness, ...)
– Optional subsets of nodes and elements for special cases.
• “ORIENT” = a transformation which is applied to the folded airbag to position it in the model.
• 3 different types are available: translation, rotation and scaling. Each ORIENT contains:
– The orient number and type (translate, rotate or scale)
– Geometrical data (location, distance, angle ...)
– Optional nodes for special cases.
• An ORIGAMI definition may contain any number of folds and orients, and a model may contain any
number of ORIGAMIs.
• Elements and nodes may be referenced in more than one ORIGAMI, but this is not advised (a node can
only have one current coordinate!)

Important Information
• Primer creates the ORIGAMI as soon as you select a folding
method
– If you want to delete the origami you have to use REMOVE >
ORIGAMI (deselect “Delete recursive”)
• “Primer-only” ORIGAMI data is written out after *END

• Some information referenced by the ORIGAMI is saved as Example keyword deck after
DYNA keyword data before *END folding in Primer (regular folder)
• Primer creates *AIRBAG_REFERENCE_GEOMETRY when
you start the folding process *KEYWORD
– Written out with the airbag model *MATERIAL
– Needed to re-create the folding process - if you change or delete *SECTION
it the folder may not work *PART
– If you need reference geometry in a different shape (e.g. 3-D) we *NODE
recommend cut-and-pasting the data into the model before *ELEMENT
running LS-DYNA … etc. etc.
• The Regular Folder stores each fold as a transformation on a *AIRBAG_REFERENCE_GEOMETRY
*SET_NODE
node set *SET_SHELL
– The transformations are not reversed when we “step back” (using *DEFINE_COORDINATE_SYSTEM
 in the menu), Primer performs n-1 folds from the reference *END
geometry condition *ORIGAMI_START
• The mesh-free folder is more complex – it stores the fixed *AXES
points, transformations and split commands *OPTIONS
*FOLD
*ORIGAMI_END

Displaying Reference Geometry Mode (in Primer)
Primer creates *AIRBAG_REFERENCE_GEOMETRY when you

start the folding process. After folding you can display the airbag in
the reference geometry condition using DISPLAY OPTIONS.
Folded Reference
geometry geometry
“Swap nodal coords > Airbag ref geom” will temporarily swap
coordinates of *NODE with any *AIRBAG_REFERENCE_GEOMETRY
data. *NODEs that do not have REFGEOM will not move.

Which Folder Should I Use?
• Use regular folder if possible • Use mesh-independent folder when
needed
• Applications: simple shape airbags &
simple orthogonal fold patterns. • Applications : complex geometries and
complex fold patterns
– Internal tethers / internal bags OK
– Internal tethers / internal bags OK
• Advantages: • Advantages:
– More fold types available – Can fold very complex geometries (with
– Keeps your square mesh which is the right approach!)
easier to manipulate later if needed
• Disadvantages: • Disadvantages:
– Need to decide and create the fold – Need to divide large parts into smaller
ones to avoid “double-cut” problem
lines in the mesh in advance
– Can create very small elements
– Very difficult for complex geometries
– Not all fold types available
– Leaves triangular mesh which can be
difficult to further manipulate

General Folding Guidelines
Internal parts – tethers, inner bags etc. should be

modelled with care: try to keep the gaps proportional.
Outer surfaces do not have to be flat for folding.
Reduce width
before tuck!
If there are tuck folds, make the mesh
narrower for the tucked section so it can fit
inside the rest of the airbag – this can be done
in the initial mesh or using the translate or
scale fold.

Two Examples of Side Airbag (SAB) Folding
SAB Folding – 2 Common Examples
• In this section we demonstrate two typical SAB fold patterns: zig-zag (or accordion, concertina,
etc.) and roll (or spiral) fold
• We also demonstrate how to create the space for the cylindrical inflator.
– Including a model of inflator in an AIRBAG PARTICLE model is not essential but useful and much more
realistic (accurate)
• The example SAB has been separated into different parts to make picking fold lines easier – this
is not a requirement for Primer folding.
• The models are provided with the course for reference – please note they are completely made-
up sab_zigzag.key sab_zigzag_inflator_insert.key
sab_start.key
inflator.key
sab_roll.key sab_roll_inflator_insert.key

SAB Folding
Read in the initial mesh model sab_start.key

The bag should lie flat in the XY plane*
*This is not strictly true – a local co-ord system option can be used to fold the bag
from any position, but starting in the XY plane will make things easier to begin with.

SAB Folding
Press keyboard shortcut “y” to

set mesh overlay to all edges

SAB Folding
Let’s start:
TOOLS  OCCUPANT  AIRBAGS

SAB Folding
regular folder
We have already created the fold lines in the mesh

so we can use the regular folder – this is the first
button on the menu

SAB Folding
First we have to DEFINE an “ORIGAMI” – Primer saves all the folding information
in this definition. This will be written out after *END.
In this example
Add a unique
ALL parts are to
ID & title here if be folded, so we
needed can select
WHOLE_MODEL.
At this point Primer will copy the current coordinates of all nodes in the ORIGAMI
and automatically create a *AIRBAG_REFERENCE_GEOMETRY card for all
nodes in the ORIGAMI in their original condition.
SAB Folding
Primer then displays the main airbag menu

Start by setting some options 
The automatic highlighting can slow

things down so change these to
“Use button”, then press “Done”.
(Note we keep the highlighting on in these
pictures to make things easy to see)

SAB Folding
Press SET_FOLD to start the folding process

SAB Folding
Every fold needs to be created using the NEW button 

SAB Folding
The first fold will be a HORIZONTAL TUCK.

Set the ANGLE first of all

SAB Folding
The first fold will be a HORIZONTAL TUCK

Set the ANGLE first of all

SAB Folding
PICK the fold line where shown

SAB Folding
Nodes moved in the fold can be

highlighted using the button shown:
Green nodes = folded
Yellow nodes = fold line

SAB Folding
Set the Fold Type to TUCK 

SAB Folding
Primer will make the fold as soon as the Fold

Type is selected.
Change the fold separation to 0.3mm*. This
determines the gap between layers for this fold.
*Larger values (e.g. 1mm) will leave a wider gap which helps reduce contact problems but
can make the final folded airbag much fatter than the real thing. Usually fabric thickness +
0.1mm gives a realistic final size and is sufficient for contact.

SAB Folding
Press NEW to start the next fold 

SAB Folding
Change the fold direction to “Reverse”

SAB Folding
Pick the fold line like before

– this time on the bottom as shown

SAB Folding
Choose the TUCK Fold Type

SAB Folding
The fold separation value is carried over from

the previous fold – no need to change this again.

Zig-zag fold

SAB Folding
We will now make the vertical zig-zag folds.

Press NEW to start the next fold

SAB Folding
You can start folding from either end. In

this example we start at the tip.
Change the Angle back to 0 deg.

Type in fold point = 360
Keep the “Reverse direction” setting but increase
the Fold Separation to “0.6” as shown.

SAB Folding
Select a THIN fold type

SAB Folding
Too small
Too small View the airbag end-on. Increase the

Scale factor using [+] (or type in) as
Too small
shown until the layers in the fold line
reach a reasonable gap thickness.
OK
OK
Too much

SAB Folding
Press NEW to move to the next fold.
1. Set fold co-ord to “400”

2. Set the direction to “Forward”
3. Turn on “SUBSET FOLDING”
4. Select THIN fold
SUBSET FOLDING: nodes for consideration

limited to those folded in previous step – this
means we don’t have to worry about Primer
grabbing other layers further away.
Primer also automatically alternates Direction

SAB Folding
In this case we want to
only fold the top layer
back over itself.
By default nodes in the lower layer will

be included in the fold line node set,
and get moved onto the fold mid plane.
Primer also thinks the total fold is quite thick,
so scales all the fold line nodes too much.
SUBSET FOLDING tells Primer to only

consider nodes that were folded in the
previous step – this excludes the lowest layer
so those nodes do not get selected.

SAB Folding
Press NEW to move to the next fold
Set the fold co-ord to “360” OR pick a node

at the point shown. Select THIN Fold.
Now SUBSET FOLDING is on Primer takes
care of changing the direction for us.

SAB Folding
Repeat this process for the remaining zig-zag

folds.
New fold  location  Thin Fold
Alternate the location between “400” and “360”
Keep SUBSET FOLDING button on.

SAB Folding
Fold line
±0.1mm
At fold 8 you will see that Primer
could not create a clean fold line.
Node not
The reason is that some nodes
within
tolerance of in the original mesh do not lie
fold line exactly on the fold line.

SAB Folding
Fold line
±1.0mm
Increase Increase the Tolerance from
tolerance to 0.1mm to 1.0mm to widen the
include it in
the fold line fold line catchment zone.
nodes

SAB Folding
The last Thin fold will be Fold 10.

Press NEW to move to the next fold.

SAB Folding
The final fold will be a THICK fold at the

point shown.
Change the angle to 900 and set the fold
separation to 20mm.
Select THICK Fold Type

SAB Folding
This creates a shape into which we

will fit the inflator using (LS-DYNA).
The best shape to make depends
on the inflator and how you decide
to fit it, so clearly that step should
be considered at this time.
Once complete, press “DONE” to
exit the SET FOLD menu

SAB Folding
Then “APPLY” to exit the main airbag folder.

Note: at this point we could also translate and rotate the whole
folded airbag into a new position (e.g. to fit seat) using
POSITION FOLDED BAG. These final “global” orients are
saved with the folding data and will be reapplied if the bag is
re-folded at a later date.
Positioning the bag outside the folder menu (e.g. using
Primer’s ORIENT menu) is also possible but if the bag is read
into the airbag folder again (for refolding) those orients will be
lost. The user would have to re-position the bag again.

SAB Folding
Primer gives various options at

this point
Choose the default “Exit with
folded and positioned bag”.

SAB Folding
Write out the model as sab_zig-zag.key

Roll fold

SAB Folding
Before introducing roll folding, please consider this simple study of mesh size. In the model
below five 250mm x 500mm airbags are rolled using Primer into a 28mm diameter initial
condition. The airbags have 1mm, 2mm,3mm, 4mm, & 5mm quad mesh. We use five identical
*AIRBAG PARTICLE cards to deploy each bag.
1mm 2mm 3mm 4mm 5mm

The smaller the mesh size, the quicker
it unrolls (results have not converged).
200,000 and 400,000 particles give
similar results.
This needs more investigation and

comparison to test data, but we
suspect that contact also influences
deployment speed.
We strongly suggest investigating the

influence of mesh size on your model’s
deployment.
Note this effect has not been seen in zig-zag folds

SAB Folding
Start with a new model or DELETE the zig-zag

folds up to this point. Press NEW to start the
next fold.

SAB Folding
This time we will create the thick 900 fold first:

Set fold point = 40, angle to 00, separation to
20mm, angle to 900.

SAB Folding
This gives us a 900

thick fold in the same
location as before.
Select NEW to create
the next fold.

SAB Folding
Reverse direction and create

the thin fold downwards at the
point shown (80).
Set separation to 0.6mm and
adjust the scale factor as before.
Press NEW to make a new fold

SAB Folding
Turn on SUBSET FOLDING to

limit nodes for consideration to
those from the previous fold.
Increase separation to 1.0mm
Change fold point to 65 and
select SPIRAL FOLD.

SAB Folding
An Archimedean spiral (radius is

proportional to angle) is used.
PRIMER attempts to keep the
characteristic element length
constant at the middle fiber of the
bag.

SAB Folding
Change the spiral scale factor to 0.5

to increase the diameter. This factor
describes the portion of total arc
length to leave unused in the middle.
That’s the roll fold finished. Press
DONE > APPLY to exit the folder

SAB Folding
Write out the model as sab_roll.key

Fitting the Inflator
We recommend adding a rigid inflator

model inside the airbag for any AIRBAG
PARTICLE analysis (see the full training
course for reasons why).
We therefore have to make a void inside
the folded airbag to accommodate the
inflator.
A geometric folder like Primer can

translate or scale individual nodes to
make a gap in the fabric, but this is not
easy. A more common approach is to set
up an LS-DYNA analysis and deform the
fabric by moving or expanding the inflator
over time.
We introduce this approach using the
model folded earlier.

The first step is to determine the exact

location of the inflator in the real folded airbag.
E.g. look at the location of the bolt holes in
the unfolded condition – the bolts should pass
through the same elements in the folded
condition.
Then consider what final shape of fold (in
Primer) could be easily expanded by the
inflator in LS-DYNA to achieve the desired
final position.

There are different methods to deform the fabric using LS-DYNA. An easy way is to use BOUNDARY
PRESCRIBED FINAL GEOMETRY (BPFG), set up in Primer:
1. Merge the inflator with the airbag model and move to desired final location
2. Create a BPFG definition – add all the nodes on the inflator (inc. retainer etc.) to the definition.
3. Using Orient – scale, shrink the inflator down to a very thin width (or project all the inflator nodes to a
plane) such that the whole part can fit inside the gap between the airbag fabric. You may need to
translate the inflator as well. There should be a reasonable gap all around the inflator – no penetration
with fabric.
4. Give the inflator a null material. Make the airbag mesh MAT ELASTIC or e.g. PLASTIC KINEMATIC
(deforms better with some bending stiffness). Add SPCs to airbag nodes you do not wish to move.
Add contacts between inflator and fabric and fabric self (make them fairly thick to avoid penetrations).
Add a suitable loadcurve to the BPFG card so the nodes move back to their reference condition
gradually over time, deforming the fabric.
5. Run in LS-DYNA. Export the fabric nodes from the final state using D3Plot (write > keyword > nodes)
6. Import the deformed nodes into Primer. Merge with the original airbag model but use “on clash, copy
only new nodes”. Primer will swap in the new node locations, the mesh will take on the deformed
shape.
7. Add a proper airbag self contact with usual settings and check for initial penetrations, crossed edges
etc.
In some cases it is better to move rather than expand different parts of the inflator during the analysis –
see DAB example in later slides.

Create BPFG (green) while the Use Display Options to swap node
inflator is the correct size/location. coordinates and check BPFG final
Then scale the nodes to the flat condition
initial condition (red).
We also selected some

nodes on the airbag for
BRFG (keeps a flat strip
next to inflator)

Combined Folding, Inflator and Case Fitting Animated GIFs
In this example the final thick fold is made by shrinking the case in an LS-DYNA
analysis. Making a thick fold like this avoids the small elements produced by
Primer’s folder and gives a realistic final shape.
Space for the inflator is made at the same
time by expanding it inside the bag using
BOUNDARY PRESCRIBED FINAL GEOMETRY.
Fixed area using SPCs

Combined Folding, Inflator and Case Fitting
In this example the final thick fold is made by shrinking the case in an LS-DYNA
analysis. Making a thick fold like this avoids the small elements produced by
Primer’s folder and gives a realistic final shape.
Space for the inflator is made at the same
time by expanding it inside the bag using
BOUNDARY PRESCRIBED FINAL GEOMETRY.

Relaxation Analysis
$: AOPT FLC FAC ELA LNRC FORM FVOPT TSRFAC
3.0 0.0 0.0 0.0 0.0 12.0 0.0 5000
• During the final stages of the folding process, TSRFAC on MAT Example of Positive ID TSRFAC
FABRIC can be also used to used to perform a relaxation analysis
1.0
• This technique “pulls” or “pushes” distorted elements into their
correct shape – the final shape (*NODEs) can cut and pasted into
TSRFAC
the model to make a more accurate initial folded condition.
0.0
Time
100ms
(ms)
• In this case, TSRFAC should be a

curve that gradually increased from
zero to one over the full course of the
analysis.
• The relaxation model should contain
*AIRBAG REFERENCE GEOMETRY
but no other *AIRBAG card.
• It usually works best when no other
motion is applied to the fabric (e.g. do
the inflator or case fitting in a separate
analysis).

Mesh-Independent Folding
Mesh Independent Folding
• Here we provide an example using the MESH-INDEPENDENT folder
• As mentioned earlier this does not require the fold and tram lines to exist
within the mesh, so more complex fold patterns can be made in a short
amount of time
• However there are some drawbacks which need consideration:
– It only creates triangle mesh (triangles behave the same as quads in MAT FABRIC)
– Holes cannot exist (add vents to the mesh later)
– A fold line can only cut though a part once (define the initial parts so this does not
happen)
– The mesh must be split (and remeshed) at every fold – this may create very very
small elements where many layers are folded together (avoid very thick folds)
– If the geometry is so complex that the split cannot be made even with the smallest
elements, the fold must be deleted or the whole folding data will become corrupt (i.e.
can’t be folded again at a later date). Delete the fold before exiting the airbag folder.
Parts cannot be
cut by a fold line Separate into different
more than once parts before folding
E.g. patch

Read in sab_mesh_independent.key. Upper and lower
layers are organised into just two parts for simplicity.
Choose the mesh-

independent folder
The first menu will

prompt to select
parts for folding…

In next menu select nodes on the

perimeter that should remain fixed
points (Primer will always keep a
node there). Here we select the
two rear corners and widest points.
Also here define the global layer
separation (e.g. 0.6mm).

Next set some OPTIONS:

Element and tramline size should
be the typical element length (e.g.
5mm). We recommend a value of
1mm for smallest polygon (can be
reduced later if needed).
Press NEW to start folding.

We will make an angled roll fold to

demonstrate the capability.
Choose Custom angle

And set the angle to 1060.

This is parallel to the top perimeter.
Note you can also define the angle
by two nodes using “Pick Line”

Select the corner node for fold point

and choose Tuck fold.

The initial preview fold will have a

jagged fold line. Press SPLIT
MESH to create a clean fold line.

All elements are remeshed as triangles. Nodes selected as fixed points remain.
Primer splits the mesh at fold and tram

lines and creates new parts in each
zone. Pick NEW to start the next fold.

Change the Custom angle to 1960.

(orthogonal to the last fold)

Select SPIRAL fold type.

Primer makes the fold along the

custom angle. Don’t forget to
SPLIT MESH.

In this case Primer cannot split the

mesh using the current settings.
In OPTIONS reduce the smallest
polygon allowed to say 0.5mm.

This is small enough to split the mesh.

Press NEW to start another fold.

Keeping the same Custom angle, create a

THIN fold downwards in the opposite
direction as shown (fold point = -65).
Split the mesh to complete the fold.

Increase the scale factor as before.

Press NEW to start the final fold.

Keeping the same Custom angle, make a

20mm thick 900 fold downwards as shown.
Split the mesh to complete the fold.

That’s it. Press DONE to exit the set fold menu.

In the final menu you can choose the exit options. First of all
choose LEAVE AS MESH INDEPENDENT ORIGAMI…

Save the model for back up – this can be read into the mesh
independent folder again for further adjustment.

After that you can exit again using the CONVERT TO

NORMAL ORIGAMI option…

This will revert the part distribution to the original model.

This converted model can still be folded using the regular folder
(all folds are translated) but not in the mesh independent folder.

DAB Folding Example
Slightly more advanced topics
Airbag CT Scan
This CT scan of a loosely folded driver’s airbag reveals the way the many layers of
fabric bend around the thick folds. A reasonably accurate model of this can be
created using a geometric folder, given the right approach. This next section will
introduce some techniques to do this.
Note this scanned airbag has a slightly different fold pattern to the example
demonstrated.
Driver’s airbag CT scan data courtesy of JSOL

Measuring & Mark Up
This fold pattern (sometimes called “Reverse Roll”) is very
common for driver’s airbags. Include the inner tethers in
the initial mesh – they make the middle section thicker.

Example of Primer Folded DAB – Classic “Reverse Roll”
The rolled sections are

created using a series of
thin & thick folds. The
base is made wider to
allow for fitting the inflator.

Example of DAB Folding – Classic “Reverse Roll”
Folding can be done on half model then copy-reflected. This saves a lot of duplicate folding
work but once reflected the full model cannot be re-folded at a later date.
We start with a regular 5mm

mesh. No effort was made
making mesh lines at exactly
the right place – there will
always be a line close enough.
We’re looking at the airbag bottom surface – the initial folds are all made in
the “Down” direction.

Example of DAB Folding
We use the JavaScript “180_degree_thin_fold_tram.js” (released with this course) to make the
initial thin folds. This can orient mid-nodes within tram lines.
We pick fold points on the

mesh to fold slightly narrower
than the real width…

… because this next thin fold

wraps over, like a roll.

Next we use a scale fold to reduce the width. Choose the fold type first, then use SETS AND
LAYERS to make a node set of just the area to scale.
Note: the scale fold is

not recommended if
mesh relaxation is
planned for the end

The fold point becomes

the centre of the scale
transformation (in this
case 0.0). Local axes are
shown in yellow. Next a thin fold…

… to bring the roll on to

the top of the airbag (now
looking at it top-side up)

Tethers folded in the centre of the

airbag cause the end sections to
have wider gaps than reality.
This will make the final folds
difficult.

This is a quite an extreme example to
demonstrate the point.
Translate & scale fold can be used

on node sets to close up the gaps
and make a more realistic
thickness.
Thin gaps require stiffer contacts which can cause instability, but
if the gaps are too wide the final folds will be too fat to fold.

Next: thick fold. One benefit of slimmed-down material is that
elements in the centre of the thick fold are not too small.
This shape
can also be
seen in the
real airbag
at this fold
Elements that are significantly smaller than their reference

size cause problems during deployment – TRSFAC (positive
ID loadcurve best) should always be used to gradually
restore the initial stresses and strains. Sudden expansion of
small elements in the centre of a tightly folded airbag can
cause incorrect deployment shape and contact issues.

We want the top folds to nest neatly inside each other as shown.
To do this we have to make the folds in a slightly strange order:
First the thick fold – estimate the thickness (separation

distance) by measuring the three layers to go inside.
Then make the thin (JS) fold at the end…
Target shape

For the next thick fold downwards, use SETS AND LAYERS to
limit the considered shells to just the top layer as shown.
Try different fold separation

values to get a good fit.
Quick shell set

Finally, a thick fold to compete this side. Use SUBSET FOLDING
to limit considered nodes to those used in previous fold.
If the layers don’t fit well, step back to the last two folds and
adjust the fold separation.
This is an extreme example of making a very slim overall

thickness – a more realistic model is probably thicker.
Now repeat folds 13 to 16 on the other side!

• How to reflect copy
The completed folded
model needs to be
copy-reflected. Here is
one approach:
1. Save as a new
model
2. Using ORIENT,
reflect fabric parts,
copy-on (elems in
same part)
3. Connect shells
along center line
using node merge
4. Write as different
model

3. Connect shells along center line using node merge 4. Write as

different
model

5. Read in original model again

6. View in reference geometry mode
7. Using ORIENT, reflect fabric
parts, copy-on (elems in same
part)
8. Connect shells along center line
using node merge
9. Write out all nodes using
CLIPBOARD or Model > write
10. Paste these nodes as
REFERENCE GEOMETRY into
the reflected, folded model

8. Connect shells along center

line using node merge
9. Write out all nodes using CLIPBOARD or Model > write

10. Paste these nodes as REFERENCE GEOMETRY into the
reflected, folded model

• That completes the DAB folding
• If you used Reflect > copy, the model cannot be re-folded using Primer
and the origami data in the model will be obsolete.
• To avoid any problems with cross-references to the old origami data,
delete the origami data from the deck (after *END) or by using Remove in
Primer.
– Do not use “Delete recursive” – it will delete the whole airbag
– Just remove the origami definition then do “Clean-up unused”
• Space for the inflator can be created using an LS-DYNA analysis as
demonstrated for the SAB.
– In this example we use BOUNDARY PRESCRIBED FINAL GEOMETRY to
expand the retainer, with some selective contact surfaces
– The method and model depends on the shape of the inflator and case
– The final geometry (node data) can be exported from a post-processor (like
D3Plot) or by using a dynain file.

3D Airbag Folding
• Some of the most complex airbags do not lie flat in any condition – these so called 3D
airbag shapes are created by stitching fabric panels together in the 3D form, then
folded using a number of methods.
• In nearly all cases the only feasible way to fold these is to use an LS-DYNA analysis
of the whole process to deform the fabric into the final shape. However as mentioned
earlier this is not a trivial task and even experienced hands can take a long time to
produce an acceptable model (with no crossed edges…).
• Some 3D types collapse to a folded-flat condition with only a few tuck folds. If this
folded-flat condition can be meshed with each layer perfectly planar (quite a large
task!), then the final folds can be made using Primer’s geometric folder.
• In some cases the collapsed state is not perfectly flat (e.g. it has many wrinkles on the
surface) but a flat model of roughly the right shape is good enough to use as a base
for geometric folding.
• In these cases, an accurate reference geometry condition can be created using a
“blow-mould” technique, where the folded or semi-folded airbag is given a soft material
and slowly inflated inside a rigid shell of the correct geometry using LS-DYNA.
Contact ensures that the airbag mesh takes the shape of the rigid shell. SPCs on the
center line, CSE=1 and other techniques can ensure a smooth final inflated shape.
Fabric nodes from the final state can be used as reference geometry in the real model.
• As mentioned earlier, a new software product (running inside Primer) to make it easier
to set-up an LS-DYNA folding analysis is under development. It is expected that
examples of 3D airbags and how to fold them will be included in the package.

3D Airbag Folding – Typical Process
• Decide the initial geometry. This will depend on what data is available from the
designer/supplier.
– Accurate CAD data of the inflated or flat 3D shape is ideal – this can then be meshed and used for
the initial model.
– If CAD of the 3D shape is not available, the 3D mesh model must be constructed by manipulating
the 2D CAD surfaces into a 3D shape, or by a stitching analysis.
– A stitching analysis is where the 2D flat panels are meshed separately, then assembled into a 3D
shape using LS-DYNA analysis. The assembly is done using 1D elements that pull the perimeters
of the part together in a virtual stitching process. The final 3D meshed shape is then used for the
initial model.
– The complete 3D mesh model should form the reference geometry for use in the final model.
• 3D to 2D step
– Often the most difficult part of the folding is to flatten the 3D mesh in the same way as the real
airbag. This is done using LS-DYNA by pulling/pushing the mesh at various points using plates,
and other tools. Care is needed to avoid penetrating mesh layers and keep the overall
shape/creases etc. as realistic as possible. For complex fold patterns, simulating the actual folding
process/machine can give the best results.
• 2D folding
– After the 3D mesh has been collapsed into a flat state, other tools are used to roll & fold the mesh
in the same way as the real airbag.
– These steps are also done in LS-DYNA.
• Inflator fitting
– At some point the inflator and other internal parts should be added to the model so the final airbag
folds nest around them.
– Often it’s convenient to wait to the end to do this, using similar techniques to those shown earlier.

Revision 1.3 2015

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Airbag Folding in Primer

Revision 1.3 2015

Airbag Folding in Primer

This is a guide to folding 2D airbags using Primer.

This is one part of a larger training course covering the

Airbag Folding in Primer

Airbag Folding in Primer

Airbag Folding in Primer

Folding schematics like these are rarely

Airbag Folding in Primer

Draw lines on fold creases

• Photograph each step (for reference and your report)

Airbag Folding in Primer

Once accurate dimensions are established, a flat (2-D) model

• If the fold pattern is not orthogonal (e.g. a tuck fold at an angle)

• These are explained in more detail later.

Airbag Folding in Primer

Create flat mesh 3. Mesh Independent (“MI”) Folder

Auto-create circle also available

These folds cannot be done with the

Airbag Folding in Primer

Airbag Folding in Primer

• “Primer-only” ORIGAMI data is written out after *END

Airbag Folding in Primer

Primer creates *AIRBAG_REFERENCE_GEOMETRY when you

Airbag Folding in Primer

Airbag Folding in Primer

Internal parts – tethers, inner bags etc. should be

Airbag Folding in Primer

Airbag Folding in Primer

Read in the initial mesh model sab_start.key

Airbag Folding in Primer

Press keyboard shortcut “y” to

Airbag Folding in Primer

Airbag Folding in Primer

We have already created the fold lines in the mesh

Airbag Folding in Primer

Primer then displays the main airbag menu

The automatic highlighting can slow

Airbag Folding in Primer

Press SET_FOLD to start the folding process

Airbag Folding in Primer

Every fold needs to be created using the NEW button 

Airbag Folding in Primer

The first fold will be a HORIZONTAL TUCK.

Airbag Folding in Primer

The first fold will be a HORIZONTAL TUCK

Airbag Folding in Primer

PICK the fold line where shown

Airbag Folding in Primer

Nodes moved in the fold can be

Airbag Folding in Primer

Set the Fold Type to TUCK 

Airbag Folding in Primer

Primer will make the fold as soon as the Fold

Airbag Folding in Primer

Press NEW to start the next fold 

Airbag Folding in Primer

Change the fold direction to “Reverse”

Airbag Folding in Primer

Pick the fold line like before

Airbag Folding in Primer

Choose the TUCK Fold Type