Circle packing — the series
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A flap costs a circle
A flap of a given length uses up every point of the sheet within that distance of it. Two flaps whose circles overlap are asking for the same paper twice — and that one observation turned origami design from an art into an algorithm.
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Packing is the hard part
Once a subject is a set of circles, designing the model is fitting them into a square. That step has no general algorithm, no known optimum, and it is where every remaining difficulty in origami design now sits.
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What joins the flaps
Circles are the rule for flaps that all hang from the same point. As soon as two groups of flaps hang from different places, the paper between them has to be paid for too — and the payment is a strip whose width is the distance between them.
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How much paper is wasted
The efficiency of a design is the fraction of the sheet its flaps can claim, and for almost every number of flaps nobody knows the best possible value. The bars in these figures are the best a search could find, which is not the same thing.
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From a packing to a crease pattern
The circles say where the flaps are. They do not say where to fold, and the step in between is a construction rather than a search — two families of crease, both determined by the packing, neither of them visible in the picture of the discs.
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Getting close instead of getting it right
When the best answer is out of reach the question stops being what it is and becomes how much is lost. For packing discs into a square the loss is measurable: a seeded search in this repository comes within a fifth of a percent of the best radius anybody has proved, and proves nothing.
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The flap nobody holds
An optimal packing is presented as an answer: here are the circles, here is where they go. For some numbers of flaps that is not what it is. The best arrangement of seven discs in a square leaves one of them free to wander over an eleventh of the sheet without changing the answer at all — and the algorithm reports one point of that region and stops.
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Two packings, one radius
A packing search reports a number, and the number is not the design. What a crease pattern is built from is the graph of which discs touch which — and at five and six flaps, runs of the same search that agree about the best radius to four decimal places come back with contact graphs that are provably not the same graph. The answer an optimiser gives has not determined the pattern it is supposed to have found.