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 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.