KIT OF PARTS

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This work develops algorithms to synthesize kit-of-part structures whose components can be reused in diverse shapes

Load-bearing structures cause significant environmental impacts due to large material mass requirements as well as energy-intensive manufacturing and construction. In addition, load-bearing structures are typically designed for a single location and use. At the end of their service, structures are usually demolished and at best material is recycled. One strategy to reduce resource use, process energy, and waste is the reuse of structural components. A promising strategy for component reuse consists in designing a bespoke kit of parts whose elements are ready to be assembled in multiple structural arrangements, fulfilling different purposes. The term ‘kit of parts’ denotes “a collection of discrete building components that are pre-engineered and designed to be assembled in a variety of ways to define a finished building”. Being able to reuse kit-of-parts elements allows to manufacture only a subset of elements compared to one-off constructions thus reducing material requirements.
Designing a kit of parts entails that dimensioning and detailing of all parts as well as designing the structure layouts are governed by reuse requirements. All parts have to fit the geometry of different structure layouts and all connections must allow multiple assemblies. In parallel, assembly and disassembly as well as handling and shipping of all parts should be considered. Example applications of this strategy have been carried out to design temporary structures including deployable structures and modular space-frame systems. However, one drawback of modular systems is their restriction to certain repetitive arrangements.
This work presents a computational workflow to design a kit of parts comprising linear bars and spherical joints that can be used to build a set of diverse reticular structures, e.g. trusses, gridshells, and space frames, whose geometries are not restricted to repetitive modular arrangements. The method has been applied to the design of a kit of parts to build the three space frame structures. Kit-of-parts bars are linear elements that are connected by spherical joints through bolts. Initial geometry and topology of the structures are given as input. The method comprises two steps. In the first step, the structure geometries and the kit-of-parts bars (length and cross-section) are optimized to enable the reuse of identical bars among structures. In the second step, the hole pattern of the spherical joints to connect the bars is optimized to reuse each joint in multiple structures.

This research has been developed at the Structural Xploration Lab, EPFL under supervision of Prof. Corentin Fivet and co-supervision of Dr. Gennaro Senatore.

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