Fabian Eidner

Abstract

Achieving near-net-zero buildings requires facades that reduce material use and operational energy while responding to dynamic environmental conditions. This research explores the co-design of a novel façade concept that integrates Phase-Change Materials (PCM) with Large-Scale Additive Manufacturing (LSAM) to create lightweight, adaptive, and circular building envelopes. The system couples passive thermal regulation through PCM with an occupant-centred ventilation control mechanism, forming a hybrid-responsive façade that mediates indoor comfort, energy performance, and user interaction. The research employs a computational co-design method to align architectural intent, material behaviour, and fabrication logic in a unified workflow. Printed geometries are optimized for thermal interaction, airflow modulation, and structural efficiency, while all interfaces are designed for disassembly and reuse. Performance is evaluated through numerical simulation, physical prototyping, and life-cycle assessment to assess feasibility and environmental impact. Overall, this research highlights the architectural and performative potential of LSAM in conjunction with PCM, and paves new ways for adaptive, circular façade solutions that support lightweight, low-energy building strategies.

Abstract

Bio-based and waste-sourced materials are emerging as sustainable alternatives to reduce resource extraction and construction waste in the Architecture, Engineering, and Construction (AEC) industry. Unlike conventional materials such as brick, concrete, or steel, they are renewable, locally available, and support circular economy principles. Agricultural fibers like hemp offer high carbon uptake and frequent harvest cycles but exhibit variability due to environmental factors. Similarly, reclaimed materials are influenced by prior use, residual performance, and inconsistent availability. These properties contrast with current manufacturing standards, which prioritize uniform materials suited for standardized fabrication. While data-driven modeling and in-line sensing offer solutions for material variability, existing workflows remain optimized for mass production and lack flexibility to integrate bio-based and reclaimed resources. This paper examines how bio-based and reclaimed materials impact design and fabrication, focusing on the capabilities and limitations of current CAD and CAM workflows. Through architectural case studies, it explores: Capabilities: How well can CAD, CAM, and simulation tools accommodate material variability? Limitations: What barriers hinder large-scale adoption, and at what stages? Opportunities: What workflow modifications can enhance adaptability? The case studies cover timber, agricultural fibers, and biopolymer-based materials, analyzed alongside their fabrication methods—milling, fiber winding/kitting, and 3D printing. Insights from these studies inform the Adaptive Production Chain (APC), a new methodology for integrating material characterization with design and fabrication. APC fosters adaptive, circular workflows, aligning material properties with production processes to promote sustainable innovation in the AEC industry.

Abstract

While primarily admired for their material efficiency and aesthetic potentials, form-active fabric structures also offer original solutions to architectural design, modulating spaces with pliable and soft surface qualities. Their application, however, is hindered by the need for a profound understanding of the relationship between morphology, structure, and materialization. To comprehend and resolve these interdependencies, architects and engineers employ the means of form-finding. Existing form-finding methods for fabric structures exist either in purely digital or purely physical mediums. This paper introduces a cyber-physical form-finding method that seeks the equilibrium state of highly articulated fabric structures through sensorial modeling and emergent behavior of interacting forces. By embracing the softness and inherent responsiveness of elastic fabrics, this research presents an interactive form-finding approach for form-active material system where real-time shape adjustments are performed through hands-on manipulation. The developed design interface enables designers and user to swiftly explore numerous fabric morphologies in their equilibrium, suggesting intuitive tangible means of design communication.