Unprecedented Structural Skins. Experiments towards an Intelligent Tensegrity Skin

Abstract

Pin-jointed prestressable structures -known as tensegrity systems- have been largely studied for over six decades, untouched in their complexity and fascination. Prior research has marginally offered interactive toolsets to design tensegrity: none without tedious procedures embedded in their resolution. Restrictions in terms of simultaneous design's topology and optimization - aggravated by lacking effective means to automate manufacturing and specially assembly of such system - have greatly disrupted and cornered their current applicability. We present results of unprecedented processes extending tensegrity systems applicability. Employing a novel approach to design's topology and optimization of arbitrary tensegrity systems, we developed means to automatically design and manufacture them. With advantages in tailoring design and production costs, we explore some speculative scenario.Therefore we present experiments towards novel processes and products aimed to revolutionized the market of lightweight structural systems, both in static and dynamic applications. Moving from tensegrity systems and their intrinsic transportability, material-economy, easy manufacture, customization and assembly -the latest expanded within our research- we propose a new standard for structural performing skin. We aim for an intelligent skin: free-form, lightweight, widely adaptable in use, and capable of embedding complex design features and functionalities. Central in addressing economical solutions to nowadays challenging tasks we present our findings, analyzing production processes and potential challenges further suggesting relevant scenarios of pertinence.Highlights: ▶Tensegrity automated production is possible linking design topology, optimization, manufacturing and assembling. ▶Two automated manufacturing approaches are outlined according to scale, functionality and use.▶Injection moulding is nowadays proofed for structural performances, cost competitiveness, easy multifunctional layer implementation.▶3D printing will favor in future robust automated customized production.