Reimagining Timber: Adaptive Structures From Out-of-Grade Wood

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BACKGROUND Timber is a cornerstone of sustainable construction, valued for its renewability, carbon sequestration potential, and low embodied energy. However, a significant proportion of structural timber is classified as “out-of-grade” due to variability in stiffness, strength, and material consistency, resulting in substantial underutilisation and waste. While advances in computational design and digital fabrication offer new opportunities to reconsider timber as a variable material system, a critical gap remains in integrating material variability, structural performance, and fabrication constraints within a unified design framework. Conventional workflows typically separate design, engineering, and construction, limiting efficiency and adaptability. This project addresses this gap by investigating how out-of-grade timber can be reconfigured into a high-performance structural system through performance-driven design, closed-loop feedback, and digitally enabled fabrication.

CONTRIBUTION Reimagining Timber is a design-led research project and exhibition presented across multiple venues. Developed under the ARC Advanced Timber Hub (Manufacturing Innovation node), the project establishes an integrated design-to-fabrication workflow for adaptive timber construction. As project lead, Dr Nic Bao co-led the research with Dr. Dan Luo and Prof. Joe Gattas, developing the conceptual framework, computational methodology, and structural integration. The project integrates topology optimisation (BESO), material-packing algorithms, and discrete assembly strategies within a unified system. Structural geometries are generated through performance-driven optimisation aligned with load paths, while constraint-based packing algorithms—implemented through recursive pattern generation and mixed-integer linear programming—enable efficient allocation of timber elements within standard stock. A closed-loop workflow is established, allowing the co-evolution of geometry, material distribution, and assembly logic. The project further incorporates augmented reality (AR)-assisted assembly and advanced fabrication techniques to enhance construction precision and interdisciplinary collaboration. Fabricated prototypes validate the system, achieving material utilisation rates exceeding 97% and demonstrating high structural and fabrication efficiency.

SIGNIFICANCE The project was exhibited at Melbourne Design Week 2025 at RMIT Design Hub and later presented at the 14th World Conference on Timber Engineering (WCTE 2025), held at the Brisbane Convention & Exhibition Centre (BCEC), a leading international platform for timber research and innovation. At Melbourne Design Week, the work was included in a curated exhibition programme under the direction of Dr Timothy Moore (Creative Director of Melbourne Design Week), evidencing strong recognition within a competitive national design platform. At WCTE 2025, the project was selected by Professor Keith Crews, a leading authority in timber engineering, demonstrating its significance within the international engineering research community. The project is a key research outcome of the ARC Advanced Timber Hub and has been featured by Wood Central, evidencing both academic impact and industry engagement. Reimagining Timber advances research in digital timber construction by establishing a computational framework that integrates structural optimisation, material efficiency, and fabrication constraints. It demonstrates a scalable pathway for transforming out-of-grade timber into high-performance structural systems, reducing waste and supporting circular construction practices. The project contributes to emerging research in performance-driven design, intelligent fabrication, and sustainable construction, positioning timber as a key material for low-carbon, adaptive, and resource-efficient building systems.