Tectonic Tessellations: A Digital Approach to Ceramic Structural Surfaces

From the beginning of digital revolution, structural surfaces drew significant attention as a realm that interweaves formal explorations, form-finding and structural optimization. However, after successful experimentation in the virtual domain, it became evident that some of the main challenges lay on how to translate these structural forms into architectural assemblies at the scale of buildings. The development of digital fabrication is crucial in this task, as means to overcome traditional constraints such as need for modular pieces, scaffolding and optimal assembly sequences.This research focuses on digital workflows that combine form finding with robotic fabrication, surface tessellation and panelization. In the past years, the use of digital tools to assemble identical modules into complex formations has achieved significant results for loadbearing walls. Expanding this line of research, the proposed fabrication system carries these experiments on additive fabrication into the production of structural surfaces. The assembly sequence involves a two-step fabrication: off-site panel manufacturing and on-site assembly. The main components of the system consist of two triangular ceramic pieces that provide structural resistance, refined surface finish, and formwork for thin reinforced-concrete layer. Panelization strategies reduce the requirements on-site work and formwork.The paper describes background research, concept, construction process, methodology, results and conclusions.