Design Concept of Variable, Flat Cut Bending-Active Shells

Abstract Bending active structures offer an efficient and sustainable way to form freeform shells by elastically deforming initially flat or linear elements. However, widespread adoption remains limited by the difficulty of reconciling structural demands, architectural requirements, and material constraints early in the design process. This paper proposes an integrated concept-design method that uses strategically placed cut-out patterns on a flat panel to combine linear ribs and thin plate elements in a single piece. A comparative study using Finite Element Analysis examines the performance of the proposed design when fabricated in plywood versus 3D-printed natural fiber-reinforced polymers. The analysis indicates that plywood, with its well-established fabrication methods and environmental profile, offers a practical solution under current conditions, whereas 3D-printed natural fiber-reinforced polymers present promising avenues for customization and material efficiency – albeit with a need for further validation of their processing parameters. By mapping the interplay between geometry, material selection, and manufacturing methods, the study underscores how early-stage design decisions can influence structural behaviour and overall environmental footprint, paving the way for future prototyping in sustainable architecture.