Vault

The research project explores the architectural potential of robotic sheet metal expansion, reinterpreting a common industrial material as a driver for design. Lightweight and structurally efficient, expanded metal sheets offer opportunities for creating strong, porous, and materially optimised assemblies.

The design process integrates computational form-finding, structural analysis, and fabrication logic from the outset. Global form is informed by stress analysis, then subdivided into triangulated and hexagonal panels to reduce weight while maintaining performance. Fabrication is carried out through a robotic setup using custom tools and jigs, with material tests guiding expansion levels and assembly sequences.

By embedding fabrication constraints early in the workflow, the research demonstrates a tightly integrated design-to-production process where material behaviour directly shapes architectural form.