STACK will pioneer a mathematical framework and develop computational design solutions for freeform surface stackability

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Key concepts

STACK will pioneer a mathematical framework and develop computational design solutions for freeform surface stackability complemented by 3D elastica theory, unlocking the potential for advanced digital fabrication workflows, such as hot blade cutting, demonstrating our technology's capabilities within the Architecture, Engineering, and Construction (AEC) sector.

STACK’s focus is on five key concepts spanning the intersection of architecture, fabrication and geometry.

Mathematical Theory Computational Design Digital Fabrication Logistics Interdisciplinary Integration

Mathematical Theory Computational Design Digital Fabrication Logistics Interdisciplinary Integration

Mathematical Theory

Geometry at the core

We systematically define and characterize the design space and capabilities of stackable structures and 3D elastica curves. Our research develops a material- and fabrication-agnostic foundation that captures the essential geometric principles enabling innovative design.

This robust groundwork informs the development of advanced computational design and digital fabrication methods by bridging abstract theory with practical application. In doing so, our approach ensures that complex design challenges are met with scalable, efficient solutions, opening new possibilities across diverse applications.

Computational Design

Augmenting creativity

STACK enables conformance to complex geometries across every phase of the value chain—from design to fabrication and logistics. By leveraging our research into stackable dual-configuration structures and the design space of 3D elastica, our computational design solution adapts these insights for a wide range of scenarios and workflows.

Integrating advanced geometric insights with robust optimization strategies, STACK supports practical applications such as compact part creation using collaborative robotics in fabrication methods like hot blade cutting and conformal 3D printing, as well as efficient planning for storage, transportation, and deployment. This integrated approach bridges theoretical rigor with real-world considerations, empowering AEC stakeholders to transition seamlessly from concept to deployment with scalable, resource-efficient solutions.

Digital Fabrication

From digital to physical

Our digital fabrication process employs hot blade cutting enabled by stackability to translate complex digital designs efficiently into precise physical forms. Utilizing an elastically deforming rod, our process executes cuts defined by 3D elastica-swept surfaces, transforming intricate design concepts into tangible outputs that integrate theory, practice, and constructional delivery.

By combining real-time measurements with predictive models, our approach enables continuous evaluation and iterative refinement of fabrication outcomes. This feedback loop minimizes deviations, streamlines operations, and reduces waste, while the gathered data further enhance our computational design tools —seamlessly connecting digital design with efficient, high-quality physical production.

Efficiency at every step

STACK is developing integrated logistics technology that leverages mathematical optimization and supply chain considerations to ensure a seamless progression from concept to deployment. By automatically generating solutions that address storage, transportation, and deployment needs, our approach will empower designers to explore complex geometries while maintaining real-world feasibility and scalability.

This holistic strategy streamlines workflows and adapts to diverse operational demands. Informed by the consortium’s industrial expertise, our research merges innovation with practicality to make advanced designs more accessible, resource-conscious, and ready for real-world scenarios.

Interdisciplinary Integration

Bridging disciplines for impactful innovation

STACK adopts an interdisciplinary approach that unites expertise from transformative architecture, innovative material processing, and automated digital production. Our integrated platform seeks to combine advanced computational design, digital fabrication, and optimized logistics to create scalable tools and solutions for the built environment and beyond.

Drawing on industry-leading practices—from pioneering freeform design and additive manufacturing to automating the production of high-precision building components at scale—our approach is designed to translate our research into practical actionable applications. By seamlessly integrating diverse disciplines, STACK aspires to deliver impactful innovation that meets real-world challenges and supports widespread industry adoption.

Project details

EIC AEC Pathfinder Portfolio

Digitalization for a novel triad of design, fabrication and materials