Alignable lamella gridshells are 3D grid structures capable of collapsing into a planar strip. This feature significantly simplifies on-site assembly and also ensures compactness for efficient transport and storage. However, designing these structures still remains a challenge. This paper tackles the inverse design problem of alignable lamella gridshells leveraging concepts from differential geometry and Cartan's theory of moving frames. The study unveils that geodesic alignable gridshells, where lamellae are disposed tangentially to the surface, are limited to forming shapes isometric to surfaces of revolution. Furthermore, it demonstrates that alignable gridshells with lamellae arranged orthogonally to a surface can be realized only on a specific class of surfaces that meet a particular curvature condition along their principal curvature lines. Finally, drawing on these theoretical findings, this work introduces novel computational tools tailored for the design of these structures.

Architectural surface panelling often requires fabricating molds for panels, a process that can be cost-inefficient and material-wasteful when using traditional methods such as CNC milling. In this paper, we introduce a novel solution to generating molds for efficiently fabricating architectural panels. At the core of our method is a machine that utilizes a deflatable membrane as a flexible mold. By adjusting the deflation level and boundary element positions, the membrane can be reconfigured into various shapes, allowing for mass customization with significantly lower overhead costs. We devise an efficient algorithm that works in sync with our flexible mold machine that optimizes the placement of customizable boundary element positions, ensuring the fabricated panel matches the geometry of a given input shape: (1) Using a quadratic Weingarten surface arising from a natural assumption on the membrane's stress, we can approximate the initial placement of the boundary element from the input shape's geometry; (2) we solve the inverse problem with a simulator-in-the-loop optimizer by searching for the optimal placement of boundary curves with sensitivity analysis. We validate our approach by fabricating baseline panels and a facade with a wide range of curvature profiles, providing a detailed numerical analysis on simulation and fabrication, demonstrating significant advantages in cost and flexibility.

We introduce a computational pipeline for simulating and designing C-shells , a new class of planar-to-spatial deployable linkage structures. A C-shell is composed of curved flexible beams connected at rotational joints that can be assembled in a stress-free planar configuration. When actuated, the elastic beams deform and the assembly deploys towards the target 3D shape. We propose two alternative computational design approaches for C-shells: (i) Forward exploration simulates the deployed shape from a planar beam layout provided by the user. Once a satisfactory overall shape is found, a subsequent design optimization adapts the beam geometry to reduce the elastic energy of the linkage while preserving the target shape. (ii) Inverse design is facilitated by a new geometric flattening method that takes a design surface as input and computes an initial layout of piecewise straight linkage beams. Our design optimization algorithm then calculates the smooth curved beams to best reproduce the target shape at minimal elastic energy. We find that C-shells offer a rich space for design and show several studies that highlight new shape topologies that cannot be achieved with existing deployable linkage structures.

We introduce the new concept of C-mesh to capture kinetic structures that can be deployed from a collapsed state. Quadrilateral C-meshes enjoy rich geometry and surprising relations with differential geometry: A structure that collapses onto a flat and straight strip corresponds to a Chebyshev net of curves on a surface of constant Gaussian curvature, while structures collapsing onto a circular strip follow surfaces which enjoy the linear-Weingarten property. Interestingly, allowing more general collapses actually leads to a smaller class of shapes. Hexagonal C-meshes have more degrees of freedom, but a local analysis suggests that there is no such direct relation to smooth surfaces. Besides theory, this paper provides tools for exploring the shape space of C-meshes and for their design. We also present an application for freeform architectural skins, namely paneling with spherical panels of constant radius, which is an important fabrication-related constraint.

We present a computational inverse design framework for a new class of volumetric deployable structures that have compact rest states and deploy into bending-active 3D target surfaces. Umbrella meshes consist of elastic beams, rigid plates, and hinge joints that can be directly printed or assembled in a zero-energy fabrication state. During deployment, as the elastic beams of varying heights rotate from vertical to horizontal configurations, the entire structure transforms from a compact block into a target curved surface. Umbrella Meshes encode both intrinsic and extrinsic curvature of the target surface and in principle are free from the area expansion ratio bounds of past auxetic material systems. We build a reduced physics-based simulation framework to accurately and efficiently model the complex interaction between the elastically deforming components. To determine the mesh topology and optimal shape parameters for approximating a given target surface, we propose an inverse design optimization algorithm initialized with conformal flattening. Our algorithm minimizes the structure's strain energy in its deployed state and optimizes actuation forces so that the final deployed structure is in stable equilibrium close to the desired surface with few or no external constraints. We validate our approach by fabricating a series of physical models at various scales using different manufacturing techniques.

In this paper we study Weingarten surfaces and explore their potential for fabrication-aware design in freeform architecture. Weingarten surfaces are characterized by a functional relation between their principal curvatures that implicitly defines approximate local congruences on the surface. These symmetries can be exploited to simplify surface paneling of double-curved architectural skins through mold re-use. We present an optimization approach to find a Weingarten surface that is close to a given input design. Leveraging insights from differential geometry, our method aligns curvature isolines of the surface in order to contract the curvature diagram from a 2D region into a 1D curve. The unknown functional curvature relation then emerges as the result of the optimization. We show how a robust and efficient numerical shape approximation method can be implemented using a guided projection approach on a high-order B-spline representation. This algorithm is applied in several design studies to illustrate how Weingarten surfaces define a versatile shape space for fabrication-aware exploration in freeform architecture. Our optimization algorithm provides the first practical tool to compute general Weingarten surfaces with arbitrary curvature relation, thus enabling new investigations into a rich, but as of yet largely unexplored class of surfaces.

Cold bent glass is a promising and cost-efficient method for realizing doubly curved glass façades. They are produced by attaching planar glass sheets to curved frames and must keep the occurring stress within safe limits. However, it is very challenging to navigate the design space of cold bent glass panels because of the fragility of the material, which impedes the form finding for practically feasible and aesthetically pleasing cold bent glass façades. We propose an interactive, data-driven approach for designing cold bent glass façades that can be seamlessly integrated into a typical architectural design pipeline. Our method allows non-expert users to interactively edit a parametric surface while providing real-time feedback on the deformed shape and maximum stress of cold bent glass panels. The designs are automatically refined to minimize several fairness criteria, while maximal stresses are kept within glass limits. We achieve interactive frame rates by using a differentiable Mixture Density Network trained from more than a million simulations. Given a curved boundary, our regression model is capable of handling multistable configurations and accurately predicting the equilibrium shape of the panel and its corresponding maximal stress. We show that the predictions are highly accurate and validate our results with a physical realization of a cold bent glass surface.

The isolines of principal symmetric surface parametrizations run symmetrically to the principal directions. We describe two discrete versions of these special nets/quad meshes which are dual to each other and show their usefulness for various applications in the context of fabrication and architectural design. Our discretization of a principal symmetric mesh comes naturally with a family of spheres, the so-called Meusnier and Mannheim spheres. In our representation of principal symmetric meshes, we have direct control over the radii of theses spheres and the intersection angles of the parameter lines. This facilitates tasks such as generating Weingarten surfaces including constant mean curvature surfaces and minimal surfaces. We illustrate the potential of Weingarten surfaces for paneling doubly curved freeform facades by significantly reducing the number of necessary molds. Moreover, we have direct access to curvature adaptive tool paths for cylindrical CNC milling with circular edges as well as flank milling with rotational cones. Furthermore, the construction of curved support structures from congruent circular strips is easily managed by constant sphere radii. The underlying families of spheres are in a natural way discrete curvature spheres in analogy to smooth Möbius and Laguerre geometry which further leads to a novel discrete curvature theory for principal symmetric meshes.

Representing smooth geometric shapes by polyhedral meshes can be quite difficult in situations where the variation of edges and face normals is prominently visible. Especially problematic are saddle-shaped areas of the mesh, where typical vertices with six incident edges are ill suited to emulate the more symmetric smooth situation. The importance of a faithful discrete representation is apparent for certain special applications like freeform architecture, but is also relevant for simulation and geometric computing. In this paper we discuss what exactly is meant by a good representation of saddle points, and how this requirement is stronger than a good approximation of a surface plus its normals. We characterize good saddles in terms of the normal pyramid in a vertex. We show several ways to design meshes whose normals enjoy small variation (implying good saddle points). For this purpose we define a discrete energy of polyhedral surfaces, which is related to a certain total absolute curvature of smooth surfaces. We discuss the minimizers of both functionals and in particular show that the discrete energy is minimal not for triangle meshes, but for principal quad meshes. We demonstrate our procedures for optimization and interactive design by means of meshes intended for architectural design.

Geodesic parallel coordinates are orthogonal nets on surfaces where one of the two families of parameter lines are geodesic curves. We describe a discrete version of these special surface parameterizations and show that they are very useful for specific applications, most of which are related to the design and fabrication of surfaces in architecture. With the new discrete surface model, it is easy to control strip widths between neighboring geodesics. This facilitates tasks such as cladding a surface with strips of originally straight flat material or designing geodesic gridshells and timber rib shells. It is also possible to model nearly developable surfaces. These are characterized by geodesic strips with almost constant strip widths and are used for generating shapes that can be manufactured from materials which allow for some stretching or shrinking like felt, leather, or thin wooden boards. Most importantly, we show how to constrain the strip width parameters to model a class of intrinsically symmetric surfaces. These surfaces are isometric to surfaces of revolution and can be covered with doubly-curved panels that are produced with only a few molds when working with flexible materials like metal sheets.

Three-dimensional structures in building construction and architecture are realized with conflicting goals in mind: engineering considerations and financial constraints easily are at odds with creative aims. It would therefore be very beneficial if optimization and side conditions involving statics and geometry could play a role already in early stages of design, and could be incorporated in design tools in an unobtrusive and interactive way. This paper, which is concerned with a prominent class of structures, is a substantial step towards this goal. We combine the classical work of Maxwell, Michell, and Airy with differential-geometric considerations and obtain a geometric understanding of "optimality" of surface-like lightweight structures. It turns out that total absolute curvature plays an important role. We enable the modeling of structures of minimal weight which in addition have properties relevant for building construction and design, like planar panels, dominance of axial forces over bending, and geometric alignment constraints.