Abstract We study the combined problem of approximating a surface by a quad mesh (or quad‐dominant mesh) which on the one hand has planar faces, and which on the other hand is aesthetically pleasing and has evenly spaced vertices. This work is motivated by applications in freeform architecture and leads to a discussion of fields of conjugate directions in surfaces, their singularities and indices, their optimization and their interactive modeling. The actual meshing is performed by means of a level set method which is capable of handling combinatorial singularities, and which can deal with planarity, smoothness, and spacing issues.

The emergence of large-scale freeform shapes in architecture poses big challenges to the fabrication of such structures. A key problem is the approximation of the design surface by a union of patches, so-called panels, that can be manufactured with a selected technology at reasonable cost, while meeting the design intent and achieving the desired aesthetic quality of panel layout and surface smoothness. The production of curved panels is mostly based on molds. Since the cost of mold fabrication often dominates the panel cost, there is strong incentive to use the same mold for multiple panels. We cast the major practical requirements for architectural surface paneling, including mold reuse, into a global optimization framework that interleaves discrete and continuous optimization steps to minimize production cost while meeting user-specified quality constraints. The search space for optimization is mainly generated through controlled deviation from the design surface and tolerances on positional and normal continuity between neighboring panels. A novel 6-dimensional metric space allows us to quickly compute approximate inter-panel distances, which dramatically improves the performance of the optimization and enables the handling of complex arrangements with thousands of panels. The practical relevance of our system is demonstrated by paneling solutions for real, cutting-edge architectural freeform design projects.

Geodesic curves in surfaces are not only minimizers of distance, but they are also the curves of zero geodesic (sideways) curvature. It turns out that this property makes patterns of geodesics the basic geometric entity when dealing with the cladding of a freeform surface with wooden panels which do not bend sideways. Likewise a geodesic is the favored shape of timber support elements in freeform architecture, for reasons of manufacturing and statics. Both problem areas are fundamental in freeform architecture, but so far only experimental solutions have been available. This paper provides a systematic treatment and shows how to design geodesic patterns in different ways: The evolution of geodesic curves is good for local studies and simple patterns; the level set formulation can deal with the global layout of multiple patterns of geodesics; finally geodesic vector fields allow us to interactively model geodesic patterns and perform surface segmentation into panelizable parts.

Inspired by freeform designs in architecture which involve circles and spheres, we introduce a new kind of triangle mesh whose faces' incircles form a packing. As it turns out, such meshes have a rich geometry and allow us to cover surfaces with circle patterns, sphere packings, approximate circle packings, hexagonal meshes which carry a torsion-free support structure, hybrid tri-hex meshes, and others. We show how triangle meshes can be optimized so as to have the incircle packing property. We explain their relation to conformal geometry and implications on solvability of optimization. The examples we give confirm that this kind of meshes is a rich source of geometric structures relevant to architectural geometry.

Motivated by applications in architecture and manufacturing, we discuss the problem of covering a freeform surface by single curved panels. This leads to the new concept of semi-discrete surface representation, which constitutes a link between smooth and discrete surfaces. The basic entity we are working with is the developable strip model. It is the semi-discrete equivalent of a quad mesh with planar faces, or a conjugate parametrization of a smooth surface. We present a B-spline based optimization framework for efficient computing with D-strip models. In particular we study conical and circular models, which semi-discretize the network of principal curvature lines, and which enjoy elegant geometric properties. Together with geodesic models and cylindrical models they offer a rich source of solutions for surface panelization problems.