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A. Aigner, S. Brell Cokcan:
"Surface Structures and Robot Milling. The Impact of Curvilinear Structured Architectural Scale Models on Architectural Design and Production.";
Talk: Id&cT09 Innovative Design and Construction Technologies - Building complex shapes and beyond., Politecnico di Milano, Mailand (invited); 2009-05-06 - 2009-05-07; in: "Innovative Design & Construction Technologies. Building complex shapes and beyond.", I. Paoletti (ed.); Maggiooli Editore, Milano (2009), ISBN: 883874369x; 433 - 445.

In the last decade Computer-Numerically-Controlled (CNC)-milling technologies enabled new possibilities in constructing complex digitally-generated architectural shapes. International projects (like Neuer Zollhof Düsseldorf, Frank O. Gehry; EPFL Learning Center Lausanne, SANAA - Sejima & Nishizawa; Kunsthaus Graz, Peter Cook & Colin Fournier) show different applications of milling technologies in the production of architecture at the end of the architectural process. We focus on an application of milling technologies at an earlier stage, namely in the architectural design process, where architectural scale models are commonly used (as a tool for design-development). In this paper we discuss an innovative application of CNC-milling technology for the generation of architectural models. We show how curvilinear structures may be milled into physical volume models. With curvilinear-engraved scale models of complex shapes, one of the biggest problems with realizing digital-generated designs is affected: the structuring and segmentation of double-curved (and thus non-developable) surfaces.
Currently, the translation of a large complex surface geometry into a buildable structure comes along with diverse difficulties and often results in clumsy and aesthetically unsatisfying solutions. We argue that the use of "structure-models" (i.e., scale models representing buildable, technically feasible structures) could help to build freeform surfaces in a more satisfying way. Such structure-models are a useful communication tool for architects and construction engineers. By generating these models, architects will be encouraged to include surface-segmentation and CNC fabrication technology already in an early stage of the design process. Furthermore and above all: physical pre-studies showing different variants of macro-surface-structure are a suitable basis for aesthetical evaluation and decision-making.

architectural model making, digital model making, CNC-milling technology, computer aided manufacturing (CAM), robot milling, structure, surface design, freeform architecture