Filigree Shell Slabs

Filigree Shell Slabs introduces a novel shape optimization-to-fabrication method that expands the scope of Coreless Filament Winding (CFW) towards the production of load-bearing components for building slabs.

A multi-stage workflow is proposed, integrating parametric design, shape optimization, stress-driven material layup, and fabrication to ensure a high level of consistency between form and materialization. The research, authored by Jorge Christie and mentored by Serban Bodea (ICD) and James Solly (ITKE) explores the use of shape optimization to comprehend the underlying logic of shell forms capable of performing under the specific requirements of the structural slab scenario.

The research integrates the inherent conditions of the material, formwork system, and robotic filament winding process into a seamless design-to-manufacturing workflow. A multi-material Glass and Carbon Fiber Reinforced Polymer (G/CFRP) system is utilized: first, shape-defining GF layers are wound on modular scaffolds. Subsequently, ribbed morphologies are added in CF and GF, with a bending-active GF plate embedded in the structure. Finally, the form of the filigree lattice is defined by multiple layers of CF strands that constitute structural reinforcement and give the piece its distinctive feel and fibrous aesthetics.

The syntax and layups developed in the process prove that CFW can be successfully applied to construct fiber lattices that approximate complex synclastic surfaces. The research result: a 10.2 Kg prototype of a slab load-bearing structure was verified structurally and withstood a load of 560 Kg while spanning 2.7m, demonstrating the effectiveness of the approach.

Author

Jorge Christie, ITECH

Tutors

Serban Bodea(ICD), James Solly(ITKE), Prof. Achim Menges, Prof. Jan Knippers(ITKE)

All images (c) Jorge Christie