Discrete design in architecture: an integrated design-to-assembly system

This paper explores the integration of digital discretisation strategies with robotic assembly to advance architectural design and production within the framework of Design for Manufacturing and Assembly (DfMA). Discretisation—understood as a digitally driven method of breaking down design into modular, adaptable parts—enables flexible, scalable systems where components can be modified without compromising structural coherence. It supports precision, efficiency, and sustainable construction practices. As part of an ongoing research project on discrete design in DfMA, this paper builds on two previously developed classification systems derived from the parametric reconstruction of built and academic case studies (ZamaniGoldeh, Dounas, & Agkathidis, 2025). The methodological classification—Computational Growth, Subdivision Surfaces, and Cross-Sectional Techniques—focuses on geometric discretisation methods. The strategic classification—Top-Down, Bottom-Up, and Hybrid—centers on the modelling logic and design progression. To validate these systems, the research employs a dual approach: digital simulation and physical prototyping. Algorithms are implemented through robotic simulations in Grasshopper. Subsequently, a selection of discrete prototypes is physically assembled, allowing for assessment of joints, accuracy, stability, and constructability. This paper provides insights into the assembly logic of discrete design systems and highlights the potential of digital fabrication workflows to transform architectural practice. Going forward, it offers valuable learnings for DfMA from design to assembly and lays the groundwork for further physical validations and scaled modelling. The outcomes reinforce the practical relevance of the classification systems and offer a foundation for future, real-scale applications of robotic-based architecture.