Project Architects Atul Desai Consultants required specialists in parametric façade consultancy to execute a massive structure of Dupont (Corian) for their new commercial structure. The challenge they faced, was that the agency dealing with the materials, did not have the skill set to solve the major intersections in the structure. It was necessary to design the whole shape, such that maximum optimization of material, time and costing could be achieved, for the entire project. The other major criterion was to actualize the architects’ design and not change it while optimizing the structure.
We did a project structure study, during which various morphologies were generated. These morphologies guided us to understand the pros and cons of each form. It also helped the design architect to add valuable inputs for adjusting the form in harmonization with their vision.
We designed three types of panels primarily classified as flat panels, singly curved panels and doubly curved panels. Flat and singly curved panels were generated by CNC cutting the flat sheets on site. Then they were fixed with the material together to achieve the required shape. The singly curved panels were bent while fixing and the steel framework backing, helped to maintain the shape of these panels.
The doubly curved surfaces had to be thermoformed, the process wherein the mould was CNC, cut into shapes and the Dupont material was placed on this mould and then vacuumed into the desired shape. This process cost almost double as that of the flat panels and thus optimizing the doubly curved surface in our design also became one of the most important criteria.
The final form generated was cost effective, with minimum material wastage. The precise dynamic façade was achieved as required by the architect.
The softwares we use help us work with iterative geometries and achieve optimized structural outputs simultaneously.