A computational workflow for crafting large-scale coral inspired modules through additive manufacturing

Abstract The purpose of this research is to optimise the design of modular organic polymer shapes inspired by coral organisms through a computational workflow, with the objective of providing any existing free-form structure with a new skin by adding a new layer composed by modules robotically manufactured. The rise of digital fabrication in architecture has led to the growth of free-form design as a popular method in the industry. This is due in part to the availability of advanced software tools such as Grasshopper (GH), a graphical algorithm editor tightly integrated with Rhinoceros’s 3D modeling tools, and the advancement of robotic fabrication technologies. GH enables designers to build complex forms through visual programming, offering a highly intuitive way to generate and manipulate free-form structures with precision and efficiency. When combined with the capabilities of robotic manufacturing, this design approach allows for the production of unique, complex modules that can be assembled into larger structures. Robotic manufacturing provides a high degree of precision and flexibility, making it possible to produce components with intricate details and variable geometries that would be difficult, if not impossible, to create using traditional manufacturing methods. The integration of computational design with robotic manufacturing also presents opportunities for sustainability in architecture. By optimizing the design and production of building components, material waste can be minimized, and components can be designed for disassemble and recycling at the end of their life cycle. This study explores the integration of these methods with Large-Scale Additive Manufacturing (LSAM) by developing a methodology and later presenting a demonstrator using an existing timber structure, which we refer to as the “Timber Skeleton” (TS). The goal is to enhance the aesthetic and functional qualities of free-form structures, such as TS, while addressing the challenges of sustainability and efficiency in construction.