Optimal design criteria for form-finding of double-curved surfaces

The development of new digital design tools and fabrication technologies stimulated a large research interest in the design and construction of free-form architecture. Free-form architecture indicates the symbolic act of freeing architecture from the limitations of pure form. During the form-finding process, the priority is on identifying the geometry that enables the optimum force flow within the structure. This study focuses on the problem of the form-finding problem of concrete double-curved surfaces. First, a suitable form-finding optimization framework to optimize shell surfaces based on the surface Stress Density method is established. This framework is based on the use of different software such as Rhinoceros, Grasshopper, and Matlab. The stress density method is chosen because it allows obtaining an optimized shape starting by few parameters: the geometric characteristics of the model, the surface density factor and the magnitude of the load. In a second step, the study is focused on a single panel of the structure. Structural analyses of this panel are carried out using the commercial finite element software SAP2000 to demonstrate that it is a shape resistant structure. Finally, a new production process for concrete double-curved surfaces is presented showing a prototype at a small scale. This process is trying to satisfy the needs of new shapes within architectural design. The proposed solution is the improvement of an existing flexible mould formwork technology and represents the first attempt to reach a reusable, reconfigurable and affordable procedure.