Shell Tectonics

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BACKGROUND Shell structures are widely recognised for their structural efficiency and material economy, enabling lightweight, high-performance architectural systems. Advances in computational design, particularly topology optimisation methods such as Bi-directional Evolutionary Structural Optimisation (BESO), have enabled the generation of complex geometries aligned with force distribution. However, translating optimised shell geometries into buildable systems remains a key challenge, especially for non-standard forms requiring the integration of fabrication constraints, assembly logic, and material systems. This limits the practical application of performance-driven shell structures in architecture. This project addresses this gap by developing a tectonic framework that integrates structural optimisation, geometric generation, immersive interaction, and robotic fabrication. An enhanced topology optimisation approach enables the co-evolution of form and performance, while functional zoning supports spatial organisation. Augmented reality (AR) allows real-time visualisation and adjustment of shell geometries, enabling designers to intuitively evaluate performance during the design process.

CONTRIBUTION Shell Tectonics is a design-led research project exploring the integration of computational design and robotic fabrication for lightweight shell structures. Led by Dr Nic Bao, in collaboration with Prof. Yi Min ‘Mike’ Xie and Dr Xin Yan, the project employs BESO topology optimisation to generate structurally informed shell geometries. The project establishes a seamless design-to-fabrication workflow, where computational models are directly translated into physical structures through large-scale robotic 3D printing. Modular PETG components are assembled using bolted connections, enabling efficient construction, reduced joint complexity, and improved transportability. By integrating AR-based interaction, parametric modelling, and robotic manufacturing, the project unifies structural optimisation, spatial configuration, and fabrication logic within a single framework, replacing conventional casting and welding with robotically fabricated, mass-customised components.

SIGNIFICANCE The project was exhibited in Quantum Habitation, the 15th DigitalFUTURES Global Workshop and Exhibition, co-curated by leading scholars including Philip Yuan, Neil Leach, Achim Menges, Mark Burry, and Mette Thomsen, evidencing strong international recognition. The work demonstrates the integration of topology optimisation, immersive interaction, robotic fabrication, and modular assembly, advancing performance-driven architectural design and construction. By linking form-finding with fabrication and assembly, it provides a viable pathway for translating computational shell structures into buildable systems. Shell Tectonics contributes to emerging research in digital tectonics, robotic construction, and mass customisation, positioning shell systems as a key strategy for lightweight and fabrication-aware architecture.