Abstract We propose a method for designing 3D architectural free‐form surfaces, represented as grid shells with beams sourced from inventories of reclaimed elements from dismantled buildings. In inventory‐constrained design, the reused elements must be paired with elements in the target design. Traditional solutions to this assignment problem often result in cuts and material waste or geometric distortions that affect the surface aesthetics and buildability. Our method for inventory‐constrained assisted design blends the traditional assignment problem with differentiable geometry optimization to reduce cut‐off waste while preserving the design intent. Additionally, we extend our approach to incorporate strain energy minimization for structural efficiency. We design differentiable losses that account for inventory, geometry, and structural constraints, and streamline them into a complete pipeline, demonstrated through several case studies. Our approach enables the reuse of existing elements for new designs, reducing the need for sourcing new materials and disposing of waste. Consequently, it can serve as an initial step towards mitigating the significant environmental impact of the construction sector.

This paper addresses the design of surface shells as assemblies of tileable, flat geometric patterns with predictable performance in response to mechanical stimuli. We design a family of tileable and fabricable patterns represented as triangle meshes, which can be assembled for creating surface tessellations. First, a regular recursive subdivision of the planar space generates different geometric configurations for candidate patterns, having interesting and varied aesthetic properties. Then, a refinement step addresses manufacturability by solving for non-manifold configurations and sharp angles that would produce disconnected or weak patterns. We devise a strategy for creating continuous variations on the geometry of individual patterns, in both aesthetics and behavior, to enrich the catalog of available designs. Finally, we simulate our patterns to evaluate their mechanical response when loaded in different scenarios targeting out-of-plane bending. Through a simple browsing interface, we show that our patterns span a variety of different bending behaviors. The result is a catalog of patterns with varied aesthetics and predefined mechanical behavior, to use for the direct design of mechanical metamaterials. To assess the feasibility of our design-to-fabricate approach, we show fabricated 3D objects with different curvatures, and compare physical and simulated experiments.

The computational fabrication community is developing an increasing interest in the use of patterned surfaces, which can be designed to show ornamental and unconventional aesthetics or to perform as a proper structural material with a wide range of features. Geometrically designing and controlling the deformation capabilities of these patterns in response to external stimuli is a complex task due to the large number of variables involved. This paper introduces a method for generating sets of tileable and exchangeable flat patterns as well as a model-reduction strategy that enables their mechanical simulation at interactive rates. This method is included in a design pipeline that aims to turn any general flat surface into a pattern tessellation, which is able to deform under a given loading scenario. To validate our approach, we apply it to different contexts, including real-scale 3D printed specimens, for which we compare our results with the ones provided by a ground-truth solver.

Abstract Moulding refers to a set of manufacturing techniques in which a mould, usually a cavity or a solid frame, is used to shape a liquid or pliable material into an object of the desired shape. The popularity of moulding comes from its effectiveness, scalability and versatility in terms of employed materials. Its relevance as a fabrication process is demonstrated by the extensive literature covering different aspects related to mould design, from material flow simulation to the automation of mould geometry design. In this state‐of‐the‐art report, we provide an extensive review of the automatic methods for the design of moulds, focusing on contributions from a geometric perspective. We classify existing mould design methods based on their computational approach and the nature of their target moulding process. We summarize the relationships between computational approaches and moulding techniques, highlighting their strengths and limitations. Finally, we discuss potential future research directions.

We introduce a novel technique to automatically decompose an input object's volume into a set of parts that can be represented by two opposite height fields. Such decomposition enables the manufacturing of individual parts using two-piece reusable rigid molds. Our decomposition strategy relies on a new energy formulation that utilizes a pre-computed signal on the mesh volume representing the accessibility for a predefined set of extraction directions. Thanks to this novel formulation, our method allows for efficient optimization of a fabrication-aware partitioning of volumes in a completely automatic way. We demonstrate the efficacy of our approach by generating valid volume partitionings for a wide range of complex objects and physically reproducing several of them.

Abstract We propose a method for the automatic segmentation of 3D objects into parts which can be individually 3D printed and then reassembled by preserving the visual quality of the final object. Our technique focuses on minimizing the surface affected by supports, decomposing the object into multiple parts whose printing orientation is automatically chosen. The segmentation reduces the visual impact on the fabricated model producing non‐planar cuts that adapt to the object shape. This is performed by solving an optimization problem that balances the effects of supports and cuts, while trying to place both in occluded regions of the object surface. To assess the practical impact of the solution, we show a number of segmented, 3D printed and reassembled objects.

Abstract We propose an optimization algorithm for the design of post‐tensioned architectural shell structures, composed of triangular glass panels, in which glass has a load‐bearing function. Due to its brittle nature, glass can fail when it is subject to tensile forces. Hence, we enrich the structure with a cable net, which is specifically designed to post‐tension the shell, relieving the underlying glass structure from tension. We automatically derive an optimized cable layout, together with the appropriate pre‐load of each cable. The method is driven by a physically based static analysis of the shell subject to its service load. We assess our approach by applying non‐linear finite element analysis to several real‐scale application scenarios. Such a method of cable tensioning produces glass shells that are optimized from the material usage viewpoint since they exploit the high compression strength of glass. As a result, they are lightweight and robust. Both aesthetic and static qualities are improved with respect to grid shell competitors.

Digital fabrication devices are powerful tools for creating tangible reproductions of 3D digital models. Most available printing technologies aim at producing an accurate copy of a tridimensional shape. However, fabrication technologies can also be used to create a stylistic representation of a digital shape. We refer to this class of methods as stylized fabrication methods. These methods abstract geometric and physical features of a given shape to create an unconventional representation, to produce an optical illusion, or to devise a particular interaction with the fabricated model. In this course, we classify and overview this broad and emerging class of approaches and also propose possible directions for future research.

We propose a novel technique for the automatic design of molds to cast highly complex shapes. The technique generates composite, two-piece molds. Each mold piece is made up of a hard plastic shell and a flexible silicone part. Thanks to the thin, soft, and smartly shaped silicone part, which is kept in place by a hard plastic shell, we can cast objects of unprecedented complexity. An innovative algorithm based on a volumetric analysis defines the layout of the internal cuts in the silicone mold part. Our approach can robustly handle thin protruding features and intertwined topologies that have caused previous methods to fail. We compare our results with state of the art techniques, and we demonstrate the casting of shapes with extremely complex geometry.

Abstract Digital fabrication devices are powerful tools for creating tangible reproductions of 3D digital models. Most available printing technologies aim at producing an accurate copy of a tridimensional shape. However, fabrication technologies can also be used to create a stylistic representation of a digital shape. We refer to this class of methods as ‘stylized fabrication methods’. These methods abstract geometric and physical features of a given shape to create an unconventional representation, to produce an optical illusion or to devise a particular interaction with the fabricated model. In this state‐of‐the‐art report, we classify and overview this broad and emerging class of approaches and also propose possible directions for future research.

We propose a new method for fabricating digital objects through reusable silicone molds. Molds are generated by casting liquid silicone into custom 3D printed containers called metamolds. Metamolds automatically define the cuts that are needed to extract the cast object from the silicone mold. The shape of metamolds is designed through a novel segmentation technique, which takes into account both geometric and topological constraints involved in the process of mold casting. Our technique is simple, does not require changing the shape or topology of the input objects, and only requires of-the-shelf materials and technologies. We successfully tested our method on a set of challenging examples with complex shapes and rich geometric detail.

We propose FlexMaps, a novel framework for fabricating smooth shapes out of flat, flexible panels with tailored mechanical properties. We start by mapping the 3D surface onto a 2D domain as in traditional UV mapping to design a set of deformable flat panels called FlexMaps. For these panels, we design and obtain specific mechanical properties such that, once they are assembled, the static equilibrium configuration matches the desired 3D shape. FlexMaps can be fabricated from an almost rigid material, such as wood or plastic, and are made flexible in a controlled way by using computationally designed spiraling microstructures.

We present FlexMolds, a novel computational approach to automatically design flexible, reusable molds that, once 3D printed, allow us to physically fabricate, by means of liquid casting, multiple copies of complex shapes with rich surface details and complex topology. The approach to design such flexible molds is based on a greedy bottom-up search of possible cuts over an object, evaluating for each possible cut the feasibility of the resulting mold. We use a dynamic simulation approach to evaluate candidate molds, providing a heuristic to generate forces that are able to open, detach, and remove a complex mold from the object it surrounds. We have tested the approach with a number of objects with nontrivial shapes and topologies.

We introduce elastic textures: a set of parametric, tileable, printable, cubic patterns achieving a broad range of isotropic elastic material properties: the softest pattern is over a thousand times softer than the stiffest, and the Poisson's ratios range from below zero to nearly 0.5. Using a combinatorial search over topologies followed by shape optimization, we explore a wide space of truss-like, symmetric 3D patterns to obtain a small family. This pattern family can be printed without internal support structure on a single-material 3D printer and can be used to fabricate objects with prescribed mechanical behavior. The family can be extended easily to create anisotropic patterns with target orthotropic properties. We demonstrate that our elastic textures are able to achieve a user-supplied varying material property distribution. We also present a material optimization algorithm to choose material properties at each point within an object to best fit a target deformation under a prescribed scenario. We show that, by fabricating these spatially varying materials with elastic textures, the desired behavior is achieved.

Mesh joinery is an innovative method to produce illustrative shape approximations suitable for fabrication. Mesh joinery is capable of producing complex fabricable structures in an efficient and visually pleasing manner. We represent an input geometry as a set of planar pieces arranged to compose a rigid structure, by exploiting an efficient slit mechanism. Since slices are planar, to fabricate them a standard 2D cutting system is enough. We automatically arrange slices according to a smooth cross-field defined over the surface. Cross-fields allow representing global features that characterize the appearance of the shape. Slice placement conforms to specific manufacturing constraints.