Due to technological innovations free-form shapes in architecture can be seen more often nowadays. For instance in façades, roofs and pavilions. In between this design shape and actual producible shape lays a complex process that has to do with approximating and subdividing this shape in economically producible panels. Restrictions for production depend on the used materials, production techniques and the method of assembly. The aim of this research is to develop a method for manufacturing free-form steel structures – with a guarantee for high accuracy – relying only on a CNC laser cutter. This methodology consist out of three parts. The first part focusses on generating a quadrangular subdivision based on the topology of the shape. The second part explains a global approach that increases the developability in the panels, while maintaining a certain accuracy to the original shape. Lastly the modified geometry is transformed to structural elements on which a preliminary structural analysis is executed to provide an estimation of the required dimensions of the elements.