Transforming a Cantilever with Fixed Joints into Trussed Configurations: A Case Study in Creative Design Thinking & Prototyping

In the design of structures, joint design significantly influences aesthetics, structural performance, tectonics, and member geometry. In this study, a Y-shaped, polyhedral cantilever with fixed joints was transformed into five different trussed configurations using universal joints. Enabled by 3D-printed plug-in joints, a full-scale trussed cantilever was repeatedly (dis-)assembled. Graphic statics principles drastically simplified the branch count and design. Beyond its structural significance, joint articulation impacts element/connector count, required cross-sections i.e. material mass and associated sustainability, and visual appeal/aesthetics. By comparing results obtained from computational and physical methods, including Karamba3D, load tests, terrestrial laser scanning the prototype’s unloaded and loaded states, and the associated mathematical quantities, this paper draws conclusions on (i) structural performance, (ii) material consumption, and (iii) complexity and architectural aesthetics. Presented research integrates architectural and structural design, teaching, hands-on experience and testing on digital and physical levels, offering insights for efficient construction, sustainable practices, modularity, and advanced manufacturing.