Integrative Design and Engineering for Timber Folded Plate Structures of Free-Form Vaulted Systems

The present research describes the comprehensive development of a timber folded plate structure, and explores the potential of the folding principle for designing free-form vaulted shells. Corrugated structures are well-known for their efficiency with regard to material saving and structural reliability, by stiffening a thin surface with the introduction of a series of folds through and optimized geometric design. Their inherent composition of discrete planar elements allows a high degree of pre-fabrication, offering the possibility to benefit from one of the most advanced sectors in the industry, thereby attaining a responsible material consumption while minimizing the ecological footprint. This paper discusses the integrative design process and construction of the Pentaura pavilion, a timber folded shell locally joined with few stiff mechanical fasteners. The authors further investigate the influence of the creasing technique in relation to its amplitude of corrugation. By employing a blend of parametric graphical tools in conjunction with real-time simulations on a Finite Element Analysis Software, it becomes straightforward to assess the feasibility of the pleating configuration, establishing a comparison between the structure’s bearing capacity, overall mass, material usage and a cross-section optimization. The interdisciplinary approach presented invigorates a close collaboration between architects and engineers throughout the design process, intertwining simultaneously the benefits of an excellent static system with a striking spatial experience.