



2021-23: Additive Manufacturing of TPU formwork for reusable casting of complex façade geometries.
This research proposes a new manufacturing workflow for the design and fabrication of precast façade panels. Structural topology optimization (TO) is used to design façade panels with optimized material distribution according to the panel’s connection to a sub-structure. Flexible Thermoplastic Polyurethane (TPU) molds are additively manufactured and repeatedly cast. The study results show that TO decreases the panels’ volumes within a predefined WWR by anywhere from 23% to 30% of the total volume, while maintaining satisfactory structural performance. Additionally, the study demonstrates the potential of additively manufactured TPU molds and hybrid TPU-PLA molds for the repeatable casting of concrete while accommodating undercuts in the complex cast geometries.
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2021-23: Employing Topology Optimization for Designing Precast Façade Modules.
Designers can use engineering problem-solving tools such as topology optimization for architectural design explorations beyond optimizing a design domain with predefined boundary conditions. Engineering, in this sense, is not just an after-the-fact consideration or an assessment tool but an integrative part of the design process. We selected the design of architectural precast concrete elements for façades as a case study to demonstrate how defining the design problem leads to different solutions.
To better understand the current practices in designing and fabricating the architectural and volumetric panels, we selected 15 precedents and analyzed their panel geometry and the grid geometry of the substructure first and then the location of the panels’ connection to the substructure. Various locations for connecting envelope assemblies to the substructure have implications on the force flow within the panels and can be used to inspire material distribution. During design of the panels, the boundary conditions might be imposed on the panel after determining the panels’ geometry and porosity. We flipped this approach by considering the connection placement first and then finding a form using topology optimization that performs best under that boundary condition.
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2019-23: Volumetric envelopes.
Knowledge embedded in centuries-old techniques offers unique opportunities in the context of digital design and fabrication. Today’s computational design and digital fabrication techniques, namely additive manufacturing (AM), are relevant to precast construction. The former allows designing complex forms while the latter facilitates fabricating them. This line of research examines AM for creating volumetric precast elements used in building envelopes.
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2019-21: 3D Printing Elastic Formwork for Casting Topological Interlocking Concrete Modules of an Arch.
With bespoke fabrication on one end, and mass production on the other end of the fabrication spectrum, this study investigates custom repetitive manufacturing through molding concrete by using 3D printed formwork. The process demonstrates a proof-of-concept for 3D printing elastic resin as a formwork for repeated casting of interlocking concrete blocks. Among the challenges are the method of digitally generating the block geometry and designing the molds to accommodate complex curvatures on four sides of a block while operating within the material limitations of 3D printing with an elastic material.