Double-layered timber plate shell. International Journal of Space Structures

This article presents a new lightweight construction system for doubly curved shells made from timber plates, inspired by the masonry vaults of Eladio Dieste. The system was developed for a specific case-study project, and general applications to other freeform surfaces are being discussed. The shells are built from two interconnected layers of structural wood veneer plates, using integral through-tenon joints for a fast, precise, and simple assembly. This allows for the construction of a series of differently shaped vaults without a costly mold or support structure. Instead, inclined joints cut with a 5-axis computer numerical controlled milling machine embed the correct location and angle between plates into the shape of the parts. This constrains the relative motions between joined parts to one assembly path. To take advantage of the benefits of such connectors, the constrained assembly paths must be considered in the fundamental design of the system, allowing for the insertion of each plate. This imposes additional constraints in the segmentation process of doubly curved shells. In order to meet the requirements and resolve the multi-constraint system, we use a global, nonlinear optimization approach. Developed as a close collaboration between architects, computer scientists and structural engineers, this article includes an experimental analysis of the influence of parametric modifications in the shape of connectors on their load-bearing performance.