Design to manufacture of fully stressed curved structures through elastic deformation of thin steel sheets with interlocking connections

The research project presents the development of a fully digital design to manufacture process chain for high‐performance curved steel elements produced by laser cutting thin steel sheets and assembled through elastic deformation. Although there have been developments in industrial robotic setups to automate steel beam bending, these processes rely on an iterative approach and are time‐consuming and costly when there is a need for high accuracy.

The paper shows how the production of tailor‐made geometric parts with interlocking connections enables the design of free‐form structure as well as the complete integration of secondary functions such as façade and mounting positions. The research is based on an integrated co‐development of the construction system, structural FEA analysis, as well as manufacturing and assembly methods. A computational tool was developed to combine geometric studies and structural analysis and to automate fabrication data. This project is situated in an industrial context to test the potential for upscaling the system and detailing techniques for the assembly of curved geometries. The potential of the system is demonstrated through the design and fabrication of a 1:1 scale canopy.