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Learning from Failure: Hybrid Fabrication of a Gridshell Canopy Structure Using Timber Battens and 3D Printers

Gökalp Kalfa

Gökalp Kalfa

Yasar University, Faculty of ArchitectureIzmir, Türkiye
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Kalfa, Gökalp
, 
Mauricio Morales-Beltran

Mauricio Morales-Beltran

Yasar University, Faculty of ArchitectureIzmir, Türkiye
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Morales-Beltran, Mauricio
, 
Elif Kir

Elif Kir

Yasar University, Faculty of ArchitectureIzmir, Türkiye
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Kir, Elif
, 
Ece Hepmutlu

Ece Hepmutlu

Yasar University, Faculty of ArchitectureIzmir, Türkiye
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Hepmutlu, Ece
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Ecenur Kizilörenli

Ecenur Kizilörenli

Yasar University, Faculty of Architecture, Universite Caddesi No.37-39Izmir, Türkiye
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Kizilörenli, Ecenur
  
10 mai 2025
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Publié en ligne: 10 mai 2025
Pages: 143 - 160
Reçu: 23 juin 2024
Accepté: 09 déc. 2024
DOI: https://doi.org/10.2478/acee-2025-0011
Mots clés
© 2025 Gökalp Kalfa et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Figure 1.

Physical form-finding workshop: funicular membranes using fabric and candle wax
Physical form-finding workshop: funicular membranes using fabric and candle wax

Figure 2.

The seven proposed designs (depicted at similar scale): three large gridshell structures on the left, smaller proposals – including the selected one – on the right
The seven proposed designs (depicted at similar scale): three large gridshell structures on the left, smaller proposals – including the selected one – on the right

Figure 3.

(a) Pre- and post-revised versions of the prototype, and (b) sketch used during the discussion on the design of the canopy for structural enhancement
(a) Pre- and post-revised versions of the prototype, and (b) sketch used during the discussion on the design of the canopy for structural enhancement

Figure 4.

Distribution of the 168 timber battens across the structure
Distribution of the 168 timber battens across the structure

Figure 5.

Standard design components of a node
Standard design components of a node

Figure 6.

Most common mistakes during the early design of the nodes: (a) excessive use of material, (b) open edges in the models, (c) cable holes interfering with timber battens, and (d) wrong positioning of the bolt holes
Most common mistakes during the early design of the nodes: (a) excessive use of material, (b) open edges in the models, (c) cable holes interfering with timber battens, and (d) wrong positioning of the bolt holes

Figure 7.

Contrasting sizes and complexities of the nodes. Node 58 connects battens of the smallest cross-section (3.5 × 15 cm), while node 30 connects battens of the largest cross-section (4.4 × 2.2 cm), as well as the “column” and “canopy” sections. It also includes holes to anchor the tension cables. Since node 30 is split for assembly, the letters U and B are added after the node number to indicate the “upper” and “bottom” positions
Contrasting sizes and complexities of the nodes. Node 58 connects battens of the smallest cross-section (3.5 × 15 cm), while node 30 connects battens of the largest cross-section (4.4 × 2.2 cm), as well as the “column” and “canopy” sections. It also includes holes to anchor the tension cables. Since node 30 is split for assembly, the letters U and B are added after the node number to indicate the “upper” and “bottom” positions

Figure 8.

Flowchart of the iterations in the design and production processes
Flowchart of the iterations in the design and production processes

Figure 9.

Assembly process of the first prototype in an open area of the campus
Assembly process of the first prototype in an open area of the campus

Figure 10.

Broken nodes in the canopy before redesign. The hand note says ‘broken bar’ and it refers to the only timber battens broken as a result of the collapse. The failure of the 3 highlighted nodes at the back was surprising
Broken nodes in the canopy before redesign. The hand note says ‘broken bar’ and it refers to the only timber battens broken as a result of the collapse. The failure of the 3 highlighted nodes at the back was surprising

Figure 11.

View of the (a) original column; details of some nodes (b) with poor performance, and (c) revised version of the column in PETG nodes
View of the (a) original column; details of some nodes (b) with poor performance, and (c) revised version of the column in PETG nodes

Figure 12.

Assembly process of the second prototype
Assembly process of the second prototype

Figure 13.

Deflection of the canopy
Deflection of the canopy

Figure 14.

Performance of the nodes during the extreme deformation of the canopy
Performance of the nodes during the extreme deformation of the canopy

Characteristics of the 103 nodes

Section Quantity wall thickness Cross section (cm) bolt diameter (mm)
Column 54 7 mm 4.4 × 2.4 5
Canopy 41 5 mm 4 × 2 4
25 4 mm 4 × 1.5 4
48 3 mm 3.5 × 1.5 3

Initial course schedule

week Stage Contents / activity
2 Understanding Freeform Gridshell Structures Form-finding methods workshop I (computational)
3 Form-finding methods workshop II (physical)
4 Designing a freeform using gridshell structures
5 Designing a Freeform Gridshell Structure Design proposals: fabrication and disassembly issues
6 3D model development (nodes, battens, organization)
7 Design of nodes & battens
8 Midterm Exam Week Delivery: Design of all nodes / 3D printing setup
9 Making a Freeform Gridshell Structure 3D printing / fabrication of battens
10 3D printing / fabrication of battens
11 Assembling of parts
12 (Dis-) assembling a Freeform Gridshell Structure Test Installation on campus
13 Disassemble / Re-assemble
14 Final Installation
15 Final Exam Week Delivery: Report & digital archive

Implemented schedule

week main activity tools / equipment
2 – 3 lectures on form-finding methods & gridshell structures (principles) none
4 workshop on funicular models & design competition explained spare fabric & melted candle wax
5 Selection of proposal for prototyping visualizations - Rhino / GH models
6 Redesign of the selected proposal & 3D model development Rhino / GH models
7 Final design was ready / Column nodes are distributed among students for design Rhino model
8 All column nodes were ready Rhino model
9 – 11 Column: 3D printing (after G-codes are prepared) & preparation of timber battens; Canopy: design of nodes is developed Rhino model, Prusa / Wanhao / Creality 3D printers, Prusa Slicer, Timber (@University's workshop)
12 Assembly test of the column basic power tools
13 – 15 Canopy: All nodes are designed and 3D printed. Preparation of all timber battens. Rhino model, Prusa / Wanhao / Creality 3D printers, Prusa Slicer, Timber (@University's workshop)
16* Full assembly of the first prototype basic power tools, scaffolding

Characteristics of the 168 timber battens

Section Quantity Cross section (cm) Average length (cm) longest - shortest (cm)
Column 54 4.4 × 2.4 49.1 94.3 − 32.6
Canopy 41 4 × 2 43.1 83.9 − 20.9
25 4 × 1.5 46.5 75.5 − 32.8
48 3.5 × 1.5 49.4 83.1 − 19.8
Langue:
Anglais
Périodicité:
4 fois par an
Sujets de la revue:
Architecture et design, Architecture, Architectes, bâtiments
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