Clustering and optimization of nodes, beams and panels for cost-effective fabrication of free-form surfaces

Abstract

Free-form surfaces are increasingly used in contemporary architectural designs for their unique and elegant shapes. However, fabricating these doubly curved surfaces using panel and frame systems presents challenges due to the shape variability of nodes, beams and panels. In this study, we propose a mesh-based computational design framework that clusters and optimizes these components together, reducing the shape variety of elements for free-form surfaces. Our method employs a vertex-based similarity metric to partition panels into user-defined groups and clusters beams based on edge lengths. A box-constrained optimization is introduced to achieve congruent faces and matching beam lengths while considering various functional constraints. Additionally, connection holes on node surfaces are clustered and optimized to allow their use at multiple locations. The practicality of our approach is demonstrated through the design and construction of a full-scale pavilion, resulting in a significant reduction in the shape variety of building elements.