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Design of freeform gridshell structures - Simplifying the parametric workflow

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DOI: 10.2749/guimaraes.2019.0507

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IABSE Symposium 2019 Guimarães: Towards a Resilient Built Environment - Risk and Asset Management
March 27-29, 2019, Guimarães, Portugal

Design of freeform gridshell structures – Simplifying the parametric

workflow
Steinar Hillersøy Dyvik, Marcin Luczkowski, John Haddal Mork, Anders Rønnquist, Bendik Manum
Norwegian University of Science and Technology, Trondheim, NO

Contacting author: steinar_dyvik@ntnu.no

Abstract
Freeform structures can provide both aesthetically interesting and material efficient solutions but
are considered a demanding task for both structural design, manufacturing and architectural design.
A free form surface is therefore rationalized into something more buildable like the gridshell.
However, a digital design process with freeform geometry can be a complex and confusing task. By
defining a gridshell as nodes(joints) and elements(members), we can set up a parametric workflow
that handles the complexity in design and analysis. Optimization and rationalization of shape,
topology, and cross-section are studied real-time, giving the designer confidence and design-
freedom. This paper explains a parametric workflow for designing freeform gridshells. Through the
design and construction of a timber gridshell pavilion with 3D printed nylon nodes, we discovered
important elements of the parametric design process of freeform gridshells.

Keywords: Free form; shell structure; surface structures; reticulated; gridshell; parametric design;
parametric; aluminum; timber; 3D print.

(members), also called a gridshell or reticulated

1. Introduction
Freeform structures can provide both aesthetically
interesting and material efficient solutions.
Freeform structures can be defined as a shape that
is neither a non-structural irregular shape (blob) or
a mathematically form-found shape.
Freeform structures are considered a demanding
task regarding structural engineering. The
manufacturing of free form structures could
demand both complex manufacturing tools and
substantial geometry rationalization.
Simultaneously, architectural design and geometric
description of free form structures could require
advanced design knowledge. A common
simplification is to construct the free form
structure with nodes (joints) and elements
surface structure.
Working with free form gridshells, one approach
can be to make project-specific software that
generates and calculates geometry [1]. One of the
main manufacturers and engineers of reticulated
surface structures, the German company MERO®,
started developing their own tube/node
constructions and design methods in the 1930s.
This paper aims for a general approach that would
apply to all kinds of gridshells. With the help of
parametric modelling software, node designs can
now quite easily be developed and analysed.
Renowned engineer Jan Knippers describes the
recent development in glazed grid shells by
emphasizing the point of not losing the
architectural vision [2]. Knippers states that the
actual limitations today lay on neither the analysis

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IABSE Symposium 2019 Guimarães: Towards a Resilient Built Environment - Risk and Asset Management
March 27-29, 2019, Guimarães, Portugal
nor the fabrication. Both the structural design and
architectural geometry are controlled and
calculated with one flexible parametric model. This
way, geometric and structural design can be better
integrated, but the main achievement is that it
gives the architect more design confidence and
thereby provides more design flexibility.
Through the design of a timber gridshell pavilion
with 3D printed nodes, we have discovered
important elements in the parametric design
process of free form gridshells. By using a work-in-
progress parametric timber toolkit (PTK)[3], the
parametric design approach gathers and organizes
relevant data for both architectural detailing and
structural analysis. The parametric workflow is
made using Rhinoceros® and Grasshopper®.
Paragraph 2 contains the papers definitions and
defines key elements and key categories for
parametric free form surface structures. It also
describes form-finding and surface subdivision.
The objective of this research project is to develop
a new method for designing parametric free form
gridshells.
Paragraph 3 explains a parametric workflow for
conceptual design free form gridshells. It suggests
a method to organize the parametric model when
designing gridshell structures and describes
optimization at three levels; shape, topology and
detail.
Paragraph 4 describes a verification of the
workflow through one completed case-project and
one work-in-progress case.
Paragraph 5 discusses the findings and suggest
further work on the topic.
2. Parametric free form surface
structures
2.1 What is a parametric free form surface
structure
Free form structures can be defined as a shape that
is neither a non-structural irregular shape (blob) or
a mathematically form-found shape [4].
mathematical form found shape can be the most
load efficient, like a parabola for a vault or a sphere
for a circular dome. On the other hand, there exist
freely shaped blobs, with little relation to structural
shape. In between, there exist a wide range of
shapes that could derive from an architectural idea
or concept, and then be post-rationalized and
optimized. A key feature of these free form
structures is the non-orthogonality of their spaces.
2.2 Finding the form
Finding the optimal form of free form surface
structures is a much-studied topic and generally
well described in [4]. The shape can be found
through methods like dynamic relaxation, particle-
spring method, trust network analyses or with
methods based on graphic statics.
The form-finding methods described in [4], shows
forms that can be difficult to control freely. For the
architect or designer, this can be a limiting factor
and it can be difficult to achieve the desired shape.
2.3 Surface subdivision
Deriving from a mesh or surface, several
techniques for subdivision exists. Advanced
methods for grid connectivity and grid-layouts are
found in [4]. In addition to the Rhinoceros plugins
by Evolute GmbH, that solves geometrical issues
for professionals, more detail on the topic of
surface subdivision can be found in [5][6]. Another
study suggests that form finding and subdivision
should be coupled in one procedure [7], and this is
also an aim for our work.
2.4 How to make free forms spaces
When constructing free form surface structures, it
is favorable to rationalize the complexity in
fabrication and thereby reduce the costs. The main
impact here is to reduce the number of singly and
doubly curved elements. There exist several
techniques for achieving a non-orthogonal space.
They include waffle-structures, lamination,
pixilation, panellation, bending, gridding and more,
however, within this scope, and the described
elements of parametric free form surfaces (2.5),
panellation, bending and gridding are the most
A relevant for the types of parametric free form
structures (2.6).
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IABSE Symposium 2019 Guimarães: Towards a Resilient Built Environment - Risk and Asset Management
March 27-29, 2019, Guimarães, Portugal

2.5 Elements of parametric free form that also managed to rationalize the construction
surface structures through hyperbolics and modulization.
The elements of a parametric free form surface In this parametric workflow, the surface is normally
structure can be named as follows: the basis for further subdivision, but it can also be
the final shape itself.
a) Surface, or shape.
b) Plate, or face.
c) Element, or edge.
d) Node, or vertex.

Figure 1. From left:

a) surface, b) plate, c) element and d) node

2.6 Types of parametric free form surface

structures
Schlaich [8] argues for lightweight structures and
focuses especially on membrane structures,
discussing membrane geometries and their
manufacturing options. Bechthold [9] categorizes
spatial structures into non-rigid (membranes) and
rigid (shells). From this category, free form rigid
spatial structures have been divided into four new
categories, depending on how it is logically
constructed, physically and within a parametric
model. The categories also reflect how the forces
are transferred.
a) Continuous surfaces, with uniform load Figure 2. From top:
transfer a) continuous surface, b) plate surface,
b) Plate surfaces - plates and edges - with the load c) continuous element surface and d) reticulated
transfer along the plate-edge surface.
c) Continuous element surfaces, with uniform
load transfer along the elements 2.6.2 Plate surface – plate/edge
d) Reticulated surfaces, or gridshells, node and
Plate surfaces can be constructed with anything
elements, with load transfer in the nodes
from masonry and precast concrete, plywood, and
2.6.1 Continuous surface CLT, to metal plates and composites [10][11][12].
One advantage of plate structures is that the skin
In order to construct a continuous surface, the can become the structure, however, both
most common material, concrete, demands a manufacturing and assembly can become very
complex (timber) falsework. Such structures were complex.
more common after the second world war, than
today, related to higher material costs and lower Parametrically, plate surfaces can be subdivided
salaries. The structures of engineer Felix Candela from a surface or mesh, or described as
and Pier Luigi Nervi are excellent examples of this, independent polygons or meshes.

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IABSE Symposium 2019 Guimarães: Towards a Resilient Built Environment - Risk and Asset Management
March 27-29, 2019, Guimarães, Portugal

2.6.3 Continuous element surface surfaces are favourable in terms of fabrication.

Reticulated surfaces are especially relevant in
Continuous element surfaces are often made of
combination with glazing since the plates are not
timber, composite or metal elements that are bent
carrying membrane forces.
into shape [13]. Other techniques include
prefabricated elements, typically in timber, that This parametric framework is developed along with
would be carved from curved glulam [14]. a work-in-progress parametric timber toolkit (PTK)
[3]. This framework has so far been successfully
The element-curves can amongst others be derived
tested at two timber truss bridges. [18]. The toolkit
from continuous subdivision curves, principal
defines the relations in any structure as nodes and
stress curves or geodesic lines [13].
elements, providing automatic procedures for
2.6.4 Reticulated surface – node/element sorting overall geometry into classes of elements
relevant for architectural design, structural
In the construction of reticulated surfaces, it is analyses, manufacturing and construction.
common to move the geometric complexity to the
node, keeping the bars straight. A typical solution
is a steel node that connects to either steel or
timber glulam bars.
Other approaches could remove the need for the
node, for instance in reciprocal structures.
There exist several techniques for parametrically
defining the nodes and elements or the wireframe
geometry. Common approaches include surface or
mesh subdivision.

3. Designing free form gridshells –

parametric framework
The manufacturer MERO has since the 1930s been
a leading specialist on the realization of reticulated
surface structures. Their method of describing and
constructing reticulated surface structures as tubes
(here: elements) and nodes is a standard
procedure. Whilst connected elements are straight
with the same connection detail in the end, the
nodes deal with the curvature. The nodes have Figure 3. Parametric workflow. Inputted geometry
different features regarding structural capacities should be assembled and organized before the
and what kind of geometries it can handle [15]. A analysis. The optimization, with help of the
review of other space structure joints can be found analyses, can feed back to several aspects of the
in [16]. With the strong interest in timber setup without changing the parametric integrity.
structures related to environmental performance,
solutions are constructed from steel node to 3.2 General rules
timber connections are becoming popular. One The parametric workflow of a free form reticulated
state of the art example can be seen in [17]. surface structure depends heavily on a consistent
data structure. It is therefore important to develop
3.1 Why free form gridshells a procedure that gathers all the data at one point,
Free form surface structures can provide both to make it consistent, yet reachable.
material efficient (light-weight) and aesthetically Our setup of parametric design thinking demands
interesting structures. In this context, reticulated the following:

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IABSE Symposium 2019 Guimarães: Towards a Resilient Built Environment - Risk and Asset Management
March 27-29, 2019, Guimarães, Portugal
• geometry should be constructed from a
geometry, i.e. nodes and elements (2.3), that
serve as basis for both design and calculations.
• geometry must be assembled, and not altered
after the assembly
• cross sections, topology and detailing (from
library or manually described) should be
prepared as possible parameters for
optimization
Figure 4. Main geometric rules (3.2.1-3.2.4)
From left: Element direction, Node normal
direction, element planes, element ordering
3.2.1 Element direction
The element vectors of a node should be adjusted
to all point in the same direction (inwards or
outwards)
3.2.2 Node normal direction
The normal of a node could be defined as one of
the following:
• the sum of all the elements unit-vectors
• a global direction (X, Y, Z)
• the normal direction of the node point to a
reference surface
3.2.3 Element planes
To avoid elements with torsion, the normal
direction of each element should be consistent.
Depending on how the node-normal is defined, this
could give different results for the elements
normal.
Usually the element plane is found as either:
• sum of the two node-vectors belonging to the
element.
• or if the shape has a reference surface, the
surface-normal at the midpoint of the element.
3.2.4 Element ordering
The data structure of the elements in a node must
be ordered based on the topology. Elements
5
should therefore be sorted clockwise around the
node.
3.2.5 Choosing the right node
Including queries in the parametric framework,
that could select based on for instance node
topology is useful when detailing[3]. Queries can
be set-up based on, for instance, lengths, number
of elements and element angles.
3.3 Optimization
With the help of the parametric engineering
software, Karamba3D, the different optimization
and rationalization approaches can be studied in
real time. The main optimization steps of a
reticulated structure are at three levels, shape,
topology and cross section, suggesting a multi-
objective optimization approach.
3.3.1 Shape optimization
The global shape, the architectural concept shape,
is initially set up with simple means for shape
manipulation within a design space, for instance
NURBS control points and weights.
3.3.2 Topology optimization
Derived from a surface, several means of grid
topologies exist open source. This can provide
several types of triangular, quadratic and
hexagonal topologies. Alternatively, custom
topologies could be setup parametrically (more in
2.3). The optimization algorithm should change the
number of U and V divisions, the type, and at the
next level adjust or remove individual elements.
3.3.3 Cross section optimization
Cross section optimization is an included feature in
Karamba3D, but it can also simply be set up using a
list of available cross sections. The algorithm
searches through the list, either separately for each
element or more general for the whole structure
and finds a cross-section that can resist the forces
in each element. This can also be called cross
section picker.
IABSE Symposium 2019 Guimarães: Towards a Resilient Built Environment - Risk and Asset Management
March 27-29, 2019, Guimarães, Portugal

3.3.4 Parametric engineering

By implementing European standards, in addition
to FEM solvers in the parametric design process,
structural feasibility can be checked at an early
stage of the conceptual design, providing the
architect more confidence in his design proposals.
With the structural analysis included in the
architectural design software, redundant design
work can be removed. From the architectural point
of view, this will give huge design freedom. An
inexperienced engineer could refuse to calculate a
strange-shaped building. If the design software can
calculate, produce the reports and make files for Figure 6. A gridshell node with six connected
export, this gap can be filled. elements.

4. Case projects - Parametric gridshell 4.2 Shellter

4.1 Printshell
Printshell was constructed in 2016 for the
Trondheim maker faire. It consists of 61 unique 3D-
printed nodes that connects to timber elements
with bolts. The form was found with dynamic
relaxation and optimized for fabrication to keep
the angles between its elements (bars) at each
node within a certain range, and to keep the length
of the elements within a certain range.
With almost no geometrical limitations in
production, the nodes demanded no post-
fabrication and they included tagging, holes for the
bolts, and a cylindrical end that would grip the
timber and keep the correct longitudinal position
under assembly.
Shellter is a case project currently under
development. The project owner is a student group
named NTNUI Koiene. NTNUI Koiene runs a net of
23 small cabins that students can rent cheaply.
With this project, they have asked for something
that stands out from the other cabins and becomes
a landmark. It is favorable with light materials that
can be transported by manual carrying and a
building system that fits prefabrication. The project
is not particularly big and structurally challenging,
but it provides a proof of concept for the
parametric workflow and the manufacturing
process.

Figure 7. Site and concept shape sketch for the

Shellter

4.3 Shellter with aluminium nodes

Figure 5. Printshell. The structure was built for the
Trondheim Makerfaire 2016. Is has been rebuilt
two times afterwards.
Aluminium for is to a little extent studied as a
structural material for free form gridshell
structures. Together with industry partners, there
is an interest to manufacture the joints with
casting, shifting the industry towards new markets.
In this case, the casting method is called robotic
patternless casting [19]. This process is used for

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IABSE Symposium 2019 Guimarães: Towards a Resilient Built Environment - Risk and Asset Management
March 27-29, 2019, Guimarães, Portugal
one-off marine productions and removes the need
of molds by robotic milling directly in the sand.
If successful, the robotic patternless casting of
aluminium nodes, together with the described
parametric workflow, will be used for mass
customization for the building industry.
Figure 9. Design concept for a cast aluminium
node “cup-node”, with bolted connections to end
brackets attached to the timber
Figure 10. Concept for a cast aluminium node with
sliding connections to end brackets attached to
timber. The brackets should be attached with long
threaded rods.
Figure 11. Traditional performance test of an
aluminium bracket. A simple FEM is now being
included in the parametric framework.
7
5. Discussion
This paper describes parametric design workflows
of free form reticulated surfaces. Node designs for
reticulated surfaces are well developed amongst
some manufacturers, but parametric node designs
are not well described for the open source market.
Describing further how nodes can be designed and
developing libraries for such, would enhance the
design of parametric freeform reticulated surfaces
and will be addressed in a further study.
6. References
[1] Scheible F, Dimcic M. Parametric Engineering
Everything is Possible. IABSE-IASS
Symposium, 2011.
[2] Knippers J, Helbig T. Recent Developments in
the Design of Glazed Grid Shells. International
Journal of Space Structures 2009;24:111–26.
doi:10.1260/026635109789043205.
[3] Mork JH, Luczkowski M, Dyvik SH, Manum B,
Rønnquist A. A parametric toolkit for
advanced timber structures 2017:14.
[4] Adriaenssens S, Block P, Veenendaal D,
Williams C. Shell structures for architecture:
form finding and optimization. Routledge;
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[5] Wallner J, Pottmann H. Geometric Computing
for Freeform Architecture. Journal of
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[6] Pottmann H, Wallner J. Geometry and
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[8] Schlaich J, Schlaich M, Bergermann S.
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March 27-29, 2019, Guimarães, Portugal

[9] Bechthold M. Innovative Surface Structures: [18] Mork JH. A parametrized process: Design and
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