Design and optimisation of grid shells for maximising both structural performance and panel similarity

Although both shape optimisation and constructability of grid shell structures have been extensively studied, achieving smooth, optimised surfaces with uniform façade distribution remains a significant challenge and an active area of research. To address this, this study proposes a novel design framework that integrates shape optimisation with a remeshing method, designing efficient grid shell structures composed of near-regular triangular faces. The shape optimisation process carefully incorporates beam self-weight and smoothness sensitivity to resolve distortion issues and ensure surface continuity. Meanwhile, a remeshing approach is proposed to approximate the optimised surface with near-regular triangular panels, significantly reducing manufacturing complexity. The feasibility and effectiveness of the proposed method are validated through multiple case studies, including the optimisation of Candela’s shell and the design of a new roof shell. The results show that, compared to traditional shape optimisation methods, the proposed method achieves a notable improvement in panel similarity (7.7 % – 34.5 %) with a minor tradeoff in compliance (＜3.0 %). Additionally, when compared with the remeshing method, the proposed method significantly reduces compliance (48.4 % – 90.4 %) while also achieving moderate increases in triangular panel similarity (4.1 % – 5.6 %). These findings highlight the proposed method's ability to effectively combine the strengths of both approaches, resulting in efficient grid shell structures with reduced manufacturing complexity. • A remeshing method is proposed to reduce manufacturing complexity. • Surface smoothness is considered to resolve common distortion issues. • Results show a 34.5 % increase in panel similarity and a 90.4 % reduction in structural compliance.