The Deep Facade is a custom cast aluminum screen that showcases the potential of additively manufactured open sand molds for casting metal facade elements. The aluminum screen covers a glass surface area of 3.5 x 2.7 m2 and has a variable thickness of 55 to 110 mm. The facade expresses the structural tensile strength of cast aluminum through the geometry of elements that are very thin and suspend locally in the air.

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It is a lightweight and self-supporting screen that takes its structural load through changes in the density of elements and the precisely calculated connectivity of the elements. Its interaction with daylight creates a dynamic atmosphere, casting intricate shadows in the room. It controls the transparency of space and vision through the density of its winding members and their angles.

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The project explores the synergy between the geometric freedom offered by 3D printing and the tectonic qualities of cast metal. We combine Binder Jetting technology for cresting bespoke molds and metal casting to make the production of custom and complex structural metal parts possible and affordable.