Tectonic tessellations: A digital approach to ceramic structural surfaces

Structural surfaces represent a realm that interweaves formal explorations, structural optimization, and innovation in construction. Computation radically advanced the design of structural surfaces; however, how to translate these structural forms into architectural assemblies at the scale of buildings constitutes the most persistent challenge. In this scenario, an approach that ties advanced digital design tools to a specific ad hoc fabrication method can produce a feasible design and construction system, which can contribute to understanding and overcoming some of the current limitations of structural surfaces. This research develops an integrated digital workflow that combines form finding with robotic fabrication, surface tessellation, and panelization. In the past years, the use of digital tools to assemble identical modules into complex formations has achieved significant results for loadbearing walls. Expanding this line of research, the proposed fabrication system carries these experiments in additive fabrication into the production of structural surfaces. The assembly sequence involves two-step fabrication: off-site panel manufacturing and on-site assembly. The main components of the system consist of two triangular ceramic pieces that provide structural resistance, refined surface finish, and formwork for the thin reinforced-concrete layer. Panelization strategies reduce the requirements for on-site work and formwork. The paper describes background research, concept, the form-finding and construction process, methodology, results, and conclusions.