This project explores the use of common desktop 3D printers for the fabrication of a bespoke lightweight timber canopy by combining readily available lumber with low-cost 3D printed connections. The highlight of the structure is a 4-meter long
cantilever made possible by the bespoke printed connections which were optimized for hierarchy of members, section profile, and tension-compression forces.

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The joints were designed with a custom software using a mesh grammar that creates reinforcement branching and structural ornaments in a streamlined design process. The process begins with a network of lines that carries information defining which members are of primary structural importance, secondary members, but also which of those are stressed under pure tension or compression. A collision dependent scaling of the initial line-network, based on hierarchy and the size of the members, returns the metric data of each element and the reach of each connection.

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This hierarchical order leads to adaptable thickening of reinforcement details as well as the addition of compression plates or a cable binder for members under tension.
Furthermore, a force-flow informed surface detailing is added using mesh subdivision. 

The benefit of this algorithmic approach is that it generates all fabrication data in a single process, including all necessary matrices for a smooth preparation of linear members and assembly data. Furthermore, with a custom algorithm we could optimize the printing orientation of all joints in order to minimize production time.

 

The canopy created as a demonstrator for this connection consisted of 157 individual timber beams and 47 unique connections. It demonstrates not only the diversity of the method presented but also exhibits how a weak material printed
out of thin plastic can be used for construction if the connections are designed and
articulated intelligently.