To provide a technique for designing and precision folding of sheets of material, and for manufacturing structures therefrom.

A process for designing and manufacturing precision-folded, high strength, fatigue-resistant structures and a sheet therefore is disclosed. The techniques include methods for precision bending of a sheet of material (41, 241, 341, 441, 541) along a bend line (45, 245, 345, 445, 543) and a sheet of material formed with bending strap-defining structures, such as slits or grooves (43, 243, 343, 443, 542), are disclosed. Methods include steps of designing and then separately forming longitudinally extending slits or grooves (43, 243, 343, 443, 542) through the sheet of material in axially spaced relation to produce precise bending of the sheet (41, 241, 341, 441, 541) when bent along the bend lines (45, 245, 345, 445, 543). The bending straps have a configuration and orientation which increases their strength and fatigue resistance.