This study introduces a novel methodological framework that combines bending-active structures with conformal 3D printing to address current limitations in architectural-scale additive manufacturing. Traditional horizontal slicing and planar layer deposition present inherent constraints for fabricating large-span elements such as roofs and floor slabs, while conventional approaches to curved forms typically require resource-intensive formwork. We propose an integrated approach that utilizes bending-active structures as material-efficient substrates for 3D printing, potentially serving dual roles as both formwork and supplementary reinforcement. The methodology incorporates a multi-axis robotic platform alongside preliminary design, software, and hardware adaptations to enable material deposition that follows structural force vectors. Through initial experimental studies at various scales, we examine the fundamental aspects of this approach – including material testing, formwork registration, and toolpath adaptation – establishing a foundation for further exploration. This paper presents the conceptual framework and preliminary findings, while specific technical aspects such as toolpath generation algorithms and structural simulations are addressed in a companion paper. By introducing this methodology, we aim to contribute to the discourse on more sustainable fabrication techniques for wide-spanning architectural elements with reduced material consumption and environmental impact.
Bamboo’s renewability, strength-to-weight ratio, and low embodied carbon make it ideal for sustainable construction. However, bamboo-slat assemblies are poorly documented, limiting their use in load-bearing roofs. This study develops a modular lightweight roof using multi-slat Guadua angustifolia Kunth and recycled Tetra Pak tiles. The system includes Type A, B, and C flat trusses connected by steel bolts and plates, fabricated from slats to maximize utilization and enable modular assembly. Buckling was analyzed using updated finite-element models for a single Type A truss and the full roof. Experimental validation included a pilot Type A truss test and a full-scale 1:1 roof test. Results indicate the critical positive buckling mode for the full roof has a multiplier of 2.96, consistent with experimentally observed lateral buckling. The full-scale roof reached 9700 N, failing by lateral buckling of the upper chords, with no cracks, and design-load displacements remained below NSR-10 limits. Residual deformations in the Type A truss were attributed to connection slip, local bearing, and post-buckling effects. Interaction between trusses, purlins, and transverse bracing ensured global stability. Overall, the modular bamboo-slat roof system demonstrates structural viability, efficient load transfer, and material sustainability, supporting lightweight roofs while emphasizing stability under extreme and uplift loading.
Deployable structures represent a light and compact typology, highly suitable for emergency situations since they can be easily transported to the place where they are needed and quickly assembled. The most common solutions use Scissors-Like Elements (SLE) as these are usually simple and lightweight structures. Although their analysis methods are well developed, the practical examples studied are almost always limited to the analysis of a few modules and insufficient for habitable architectural solutions. These studies generally focus on static or kinematic analysis of the deployment, or end-state analysis. To design and use these structures with guarantees, a better knowledge of how the deployment process works is necessary. This need is even greater for structures that encounter incompatibilities during deployment. Despite the existing literature, studies are usually restricted to a single or a few modules. The reality of these structures is much more complex than what has been studied so far. Therefore, the purpose of this study is to help understand the functioning of these structures in their deployment process from a more practical point of view, so that it serves as support for the designers of this structural typology.
This paper presents a pre-rationalization approach that embeds constructive logic directly within the geometric definition of doubly curved structures, enabling their realization through low-tech methods. The approach focuses on geometric constructs characterized by two key properties: one family of coordinate curves is planar (PU-property), while the other generates singly curved, developable strips (V-strips). By operating within a parameter-driven framework, the method defines a coherent design space that allows continuous morphological exploration while preserving the geometric properties required for fabrication and assembly. The approach is demonstrated through the design and construction of a bamboo structure derived from a Dini-type geometry. The case study shows how pre-rationalization enables falsework-free construction by directly linking geometric properties to fabrication strategies, while extending traditional bamboo techniques to accommodate complex, predetermined geometries. Overall, the work highlights the potential of pre-rationalized geometry as a framework for integrating form generation, material behavior, and construction logic within sustainable architectural practice.
This paper aims to introduce a fabrication-driven design strategy called “nesting” and to highlight its key characteristics and potential for a more sustainable future. Nesting is an innovative approach to ecological freeform shell construction, in which the shell is subdivided into nested, stackable components—resembling a set of Russian dolls—where each piece is fabricated and assembled sequentially using additive or subtractive methods. By integrating construction-aware geometric principles, it enables designers to optimize material use and fabrication time, supporting near zero-waste production. This strategy was explored through two six-credit Advanced Design Studios within the NAAB-accredited architecture program at the California College of the Arts (CCA). Studio projects included the workflow, design, and fabrication of cityTREE, a nested tower-like green biome designed to purify air. Additionally, Cocoon, a 2.9-meter-tall 3D-printed nested sculptural column, was developed to investigate the pedagogical applications of nesting in architectural education. Cocoon was subsequently fabricated at the Autodesk Technology Center in San Francisco to explore alternative approaches to freeform shell construction in practice. In this paper, after outlining the definition, logic, and characteristics of nesting strategies, the authors discuss the benefits of nesting in the education of future architects and builders, explaining its pedagogical significance.
