Informing deformable formworks: Parameterizing deformation behavior of a non-stretchable membrane via kerfing

Abstract

The process for constructing freeform buildings composed of many non-repetitive shapes and waste-free formwork systems remains relatively unexplored. This research reviews a method for fabricating complex double-curved shapes without utilizing single-use formworks. This work answers questions regarding the manufacturing of these shapes in an environmentally-friendly and economic fashion. The proposed method, called a "transformative formwork," could replace state-of-the-art CNC-milled molds and is potentially suitable for large-scale construction. The transformative formwork uses a stretchable membrane or "interpolation layer" that can be manipulated into any curved surface by using vertical bars capable of being rearranged into different heights. Here, to accurately generate most of the smooth, double-curved surfaces, laser kerfing is used for bending interpolation layer into almost any complex shape. A parametric model simplifies local or global changes to the density of the kerfing patterns, modifying the deformation behavior of the layer. Several kerfed interpolation layers produced for four transformative formworks showed that the application of this method.