Waste derived from constructions and demolitions creates an opportunity to lower the carbon footprint of buildings. As bricks and concrete make up two of the most common construction materials world-wide, once the buildings they are built into, reach their end life, a large portion of the waste becomes available for reuse, rich in properties such as compressive strength and mass. If this waste is placed back into buildings, their carbon footprint can be massively reduced, while saving up on having to extract new raw and natural resources. In an effort to reduce the amount of construction and demolition waste (CDW) derived from the future generation of buildings, innovation and technologies are necessary. In the past several decades, robotic applications have made a great impact in many industries. Thanks to its efficiency, automated processes and flexibility of use, robotics has proven to be successful in manufacturing and assembly processes which can now be customized for architectural practices like the digital fabrication of new structures with the potential of implementation of new materials . If robotic manufacturing has the potential of upcycling CDW in the construction process, then buildings can have a smaller environmental footprint. Further research into experimenting with this waste material implemented into 3D printing with a 6DOF robot arm is necessary. Key words: Upcycling, Waste material, CDW, Low-Carbon Buildings, 3D Printing, AMoC, Robotic fabrication

Improved productivity and a higher level of sustainability are modern day challenges faced by the building industry that are currently being and could further be solved by a higher degree of automation. Freeform architecture is still in its infancy but the demand for it is growing. Reusable building elements are a rarity in freeforms. This thesis aims for the implementation of a new node and beam system for increased reusability and for more automation in the construction of building facades. This thesis introduces a novel reusable node and beam system for use in the automatic assembly of freeform architecture. By optimising input shapes, applying computational placement of the elements and generating instructions for robotic systems, the building sector can not only improve its productivity and reduce its emissions, it can furthermore revolutionise the stylistic nature of architecture and facilitate the fluid adaptation of new forms and functions.

The power of sound is immense. It provides an immersive experience for the user in many different forms, such as noise, melodies, voices or even a song. It is a tricky genre unlike light and temperature, and is highly complex to predict and control the user behavior in terms of sound. Thus, the intention is to correct the acoustics as a post-activity in a real-time response. It can be visually depicted through a sound responsive surface which enhances the acoustical experience of a user. The goal is to realize a physical working prototype which can be tested for proof of concept and responsive alertness to real time sound data. The objective is to enhance the user experience by developing a sound responsive skin triggered with real time sound and study its impact on the acoustic performance in an open space. An acoustic plugin is also developed to integrate the calculation process within the initial iterative design process.

The Dutch population is aging and therefore the Netherlands requires more capacity in care since this is currently not enough. Living independently as long as possible is a solutionand this solution corresponds to the wishes of elderly. Therefore the purpose of this research is to answer the following question: ‘How can architecture extend independent living while supporting elderly (65+) in their feeling of independence in daily life?’ Three types of independence are identified and discussed: the physical, the mental and the emotional independence and these are placed next to the different types of elderly. Because of the importance of feelings in relation to tangible requirements, anthropology and epistemology are the most used methodologies in this research. A difference has been made between environments that stimulate/heal and between environments that help/deals with your abilities. Nature has a big impact on the physical and mental independence, while people also like to show their identity as well as having their own place, which allows them to create a home feeling. Since every person is different, the environment should be diverse so this place can be inclusive. A neighborhood should stand on its own in order to let the people live independently for as long as possible. When growing old your health will deteriorate, this is confronting. Architecture is changeable, life is not. With the identified design options from this research, a built environment can be created that stimulate each person to be independent, physically, mentally and emotionally.

The current thesis aims to explore the potential of producing large-scale structural cast glass elements with the help of 3d printed sand moulds. Until now, mostly small blocks from structural cast glass have been generated in the building industry, revealing a research gap regarding massive components. Apart from the size, the unlimited shape potentials of cast glass have hardly been explored so far. This is because glass casting can be a very challenging process when it comes to the solidification of the material which needs to be completed under specific program settings. Except from the brittleness of the body during the annealing process, it can take months, even years for a large-scale element to be completed, because of the full controllable conditions under which the annealing process takes place. In addition, the mould types that are currently used for cast glass components present several restrictions such as the manufacturing costs, the accuracy or the sizing. An existing glass slab in the Acropolis museum, in Athens, was chosen to embody the research goals. The slab is located on top of archeological discoveries making the need for transparency necessary. The current slab consists of float glass panes with a concrete substructure which severally restrains the viewing. The thesis aim is to develop a free-form monolithic slab exclusively from cast glass without the need of external substructure. In order to address the above demands, the topology optimization method was introduced. Several algorithms of topology optimization have been developed. A compliance-based optimization was demonstrated as the most appropriate for the specific project. Obtained from the literature framework, the main principles that the design follows gravitate towards the structural, cast glass and manufacturing requirements. The external applied load, in addition to the allowable structural values were calculated. The importance for a flat upper surface, where a safety float glass layer of a permitted deformation should be laminated, was established. Regarding the cast glass demands, it is necessary to acquire a design with smooth surfaces, round edges and uniform distributed material throughout the entire model. For the current project, the optimized slab is decided to mainly consist of borosilicate glass.. A slab separation is crucial for transportation reasons. After the definition of the main design principles that the final product should respect, the design development was conducted with the combination of three methods: topology optimization, manual design and structural validation. The final result of the optimized slab successfully fulfills the preset design criteria, as the obtained structure presents 55.2% less mass than the solid version that was initially designed to replace the existing slab in the museum. In addition, a more efficient material distribution in the optimized model renders the slab more compatible for the cast glass annealing process. The result of the topology optimization technique was a quite complex geometry which is not that effective to be produced in the conventional moulds that are currently available for cast glass applications. Therefore, a new technique needed to be explored, which follows the 3d printing evolution in the building industry. The main restriction of the printed moulds is the limited available sizing that the commercial printers provide. As a solution to this problem, the separation of the large-scale mould into smaller segments was studied, as well as the development of the connecting system of these parts. The entire fabrication technique, from the moulds printing method, to the assembly components and glass melting was investigated. Finally, the transportation and integration of the slab into the building was explored, concluding with structural solutions that respect the museum and the assembly order that the slab can be attached on it.

The building sector is responsible for 40% of worldwide carbon emissions, of which 8% can be attributed to concrete construction. With an increased demand for housing, this percentage is bound to increase. This thesis sheds light on strategies for reducing the environmental impact of concrete construction by investigating the potential of structural optimization and additive manufacturing. It concludes that in its current state, additive manufacturing is not able to address the environmental impact. Therefore, other potential strategies were explored, resulting in the following hypothesis: Fabrication-aware, structurally optimized floor slabs can significantly reduce the environmental impact of concrete construction. This hypothesis resulted in a derivative-free – fabrication aware – optimization methodology combining shape and size optimization to find the optimal form of a thin-shell inspired flooring system. A life cycle assessment resulted in an overall environmental footprint reduction that ranges from 60.1% to 79.8% compared to conventional flooring systems in a hypothetical office building. This shows the effectivity of flooring systems that take advantage of membrane action and the impact of increasing structural efficiency to reduce the environmental footprint of concrete structures.

The thesis focuses on developing a workflow that utilizes an interactive flexible mold as a means of designing and fabricating freeform surfaces. The focus will be on automating a flexible mold (Re-De-Form) and use it to study and fabricate freeform surfaces. Currently, the technology associated with Re-De-Form can produce complex surfaces with double curvature. One of its predecessors, FlexiMold, consists of pins which the user moves manually after reading their position from the digital model of a surface (Asut and Meijer, 2016). The system, however innovative, lacks accuracy, to be realized as a design tool for freeform surfaces. The automation will provide with the precision and accuracy needed for a freeform surface to be produced, as well as reduce the time needed for the digital freeform to be casted onto the physical freeform. The designer is freed from the obligation to place the mold pins each time a minor change in the digital model occurs (Asut, Eigenraam and Christidi, 2018). The validity of the method is tested through the design of a timber gridshell example and its panel fabrication. This includes form finding, structural and cross-sectional study and freeform panelization. A 3x3pin small scale model of Re-De- Form that deforms according to the respective freeform digital model, has been built. Additionally, a Graphical User Interface (GUI) associated with the manipulation of the surface ensures the clarity and intuitiveness of the method to the user. The final product combines physical and digital modelling into a fast, accurate, intuitive and reciprocal freeform design tool.

In the context of western linear resource culture, this work represents a socio-technical approach to circularity in the built environment. Object-oriented programming is explored as design method for collaborative domestic environments, in particular to promote circular cooking adapted to local socio-cultural practices.

The aim of this thesis is to present the outputs of a project in which pattern kerfing techniques are explored for producing responsive freeform panels out of wooden plates. Relevant research such as the ones presented by Ivanišević (2014), Zarrinmehr et al. (2017) and Ohshima et al. (2013) have shown that it is possible to bend a wooden plate by carving patterns on one or two sides of it. By this means, the plate is able to perform both single and double curved surfaces depending on the pattern design. The main objective of this research is to find out the relationships between the geometric parameters of the pattern and the bending capabilities of the plate and to put forward a formalized method for the design and fabrication of three-dimensional, freeform and responsive surfaces. These findings lead to complex pattern designs which enable the plates to perform three dimensional and freeform curved surfaces. Moreover, these panels can be actuated as responsive building components which answer the changing performance requirements in a space. In this research, acoustic performance is addressed by designing panels which respond to the changing acoustic needs of a lecture room. The applied research methods on the flexibility involve experiments with physical models and a simulation in which the effect of the geometric parameters of the pattern on the bending capabilities are further elaborated. The acoustic performance is measured and calculated by means of multiple acoustic measurements. This research outputs three main items. The first one is a parametric definition which was used to design pattern variations in order to achieve various three-dimensional freeform surfaces produced by pattern kerfing out of wooden plates. This definition is applicable in different design problems in which the design of such surfaces is needed. The second output is a series of prototypes which are produced using laser cutting and CNC milling in order to test the actual bending capabilities of the produced panels and to measure the acoustic performance based on the defined parameters related to the geometry and composition of the panels. The last output is a case study in which the developed design and fabrication techniques are demonstrated for designing a teaching environment with better acoustic performance.

In the current times, the world context is focused on trying to incorporate hybridity into various industries. There is a certain research gap between architecture and soft robotics where inflatable architecture has been implemented and architectural robotics has also been implemented but a combination of pneumatic robotics has not been explored much. In this aim, my thesis explores the possibility of integrating Soft robotics into an architectural design approach leading to the symbiosis of digital and physical. The goal of the thesis is to develop a computational design approach for integrating spatial experience into design. The Intersection of robotics and spatial design explores a new tangent in architecture where the relationship between the human and space is constantly challenged and enhanced using sensors, actuators, responsive materials and ambient intelligence. The design represents an ever-changing living environment where human social behaviour not necessarily with space dictates the plasticity of the environment. The soft robots would be used as a means to highlight and explore how spaces could react to humans on a material scale.

This thesis is a inquiry into the idea of involving a human aspect in digital fabrication process, creating a poetic expression by developing a open dialogue between digital tools and the designers.

When designing for structural performance, the geometry of the load-bearing elements is crucial for achieving the required stability. This is even more important in structural forms, such as shells and arches that are predominantly designed by their structural requirements. However, the typical design process starts with the design by the architect, and the subsequent analysis and development by the structural engineer, resulting in inefficiencies, not only in the process but also in the sub-optimal result, as the more developed a project, is, the least effective and more costly it is to optimize. Therefore, this report outlines the development of an automated pipeline that integrates the whole lifecycle of a structure, from conception to end-of-life. The focus is on developing an integrated workflow for designing and fabricating a structurally optimized shell using computational methods for form-finding, structural and lifecycle analysis, as well as fabrication, with the end goal of facilitating an automated additive manufacturing production. The structure should be able to withstand applied wind and snow loads using construction materials that are strong in compression, such as earth as a load-bearing material. The design should also be adaptable, within the limits of the material strength or the spatial constraints of the system. In the beginning, the topic is introduced and the research framework is defined. The relevant laboratory and numerical tests are mentioned. Next, literature research is conducted in the relevant fields. More specifically, the research are avenues are divided into form-finding shell structures utilizing computational tools, in earth as a construction material and in additive manufacturing in construction, as well as context. Then, a research by design method is adopted in two directions; a physical set-up and workflow for robotic additive manufacturing with earth is developed, as well as an optimal mixture that makes the most of the capabilities of the developed set-up. Next, a computational form-finding and digital fabrication process that are informed by the developed material and physical setup are defined. The generated form will be evaluated with finite element analysis (FEA) software. The algorithm integrates stress line additive manufacturing principles to direct load paths. The resulting forms are compared with corresponding non form-found and form-found shells in terms of material reduction, as well as with standard construction for environmental impact. This project contributes towards the establishments of an optimized scientific workflow bridging the gaps between design and manufacturing, as well as the development of standards for assessing the safety and environmental advantage of 3D printed structures.

Bioreceptivity is a natural phenomenon that has been observed on building material for many years. Bioreceptivity is when materials are being colonized by one or more species of living organisms without necessarily going under biodeterioration. (Guillitte, 1995) Based on the literature, bioreceptivity depends on three main factors: on climatic conditions, the topology of the colonized element and the material. By considering these variables, this research focuses on engineering a workflow capable of supporting bioreceptivity-oriented design. More specifically, it investigates how computational performance analysis and optimization can support the integration of bioreceptive materials in customizable building elements, which could be produced by digital fabrication. For research purposes, the research is split in two main parts which run in parallel. This research takes as a case study mosses, which generally cannot withstand high solar radiation and are dependent on water for their survival and reproduction. The first part, investigates on a digital model, how surface topology modifications could improve bioreceptivity by reducing the solar radiation of a surface while directing water over them. This is approached by a script which examines through a case study, to what extent the solar radiation of a surface topology could be reduced through topological modifications and which factors influence it. Even if the average solar radiation of the case study was significantly reduced through an optimization process, it is not clear to what degree topology can contribute to the improvement of bioreceptivity because this fact can only be validated physically. The second part, focuses on lime-based mortars and examines how their composition can affect bioreceptivity. Based on the literature, material properties like high water capacity, high water retention, permeability and high total porosity can benefit bioreceptivity. Four different lime-based mortars were tested, through laboratory experiments, seeking the relation between their water transport behavior and bioreceptivity. Grain size distribution in combination with binder to aggregate ratio are the main factors which influence mortars’ transport behavior. In order to observe the relation between their water transport behavior and bioreceptivity, a moss growth experiment was conducted in a controlled environment. The short timeframe of the experiment makes it difficult to draw definitive conclusions. The methodology that was developed in these two parts, is finally attempted to be combined in a bioreceptivity-oriented design approach in order to express a new architectural vocabulary. Through a research-by-design approach, three design approaches are conceptualized, compared and prototyped, raising the potential of bioreceptive applications.

Research and development in additive manufacturing with concrete has become more widespread over the last decade. The processes developed range from concrete extrusion, to digital fabrication of formworks and the unification of formwork and reinforcement. Although they enable the production of increasingly material-efficient structures, the individual processes still face various challenges such as implementation of reinforcement, geometrical limitations, scaling and formation of cold joints, in particular because of the layer-based process. This research proposes an alternative method of producing concrete formworks dubbed ‘Eggshell’. Combined with a novel casting technique, its aim is to overcome these challenges and make material-efficient concrete production possible. As concrete is the most used construction material in the world its influence on the construction industry is unprecedented. Of the construction costs of concrete, formwork typically makes up 30-80% of the costs. This means formwork considerations are often a key driver in determining the design of concrete structures. Materials used to construct the formwork also have a big impact on the total ecological costs of the concrete building components. As the lifespan of all formwork is finite, this adds to the already considerable amount of waste generated by the building industry. Furthermore, traditional formwork made from steel or wood is ineffective in producing the non-standard, (double) curved geometry that characterizes many contemporary architectural designs. Using innovative means of formwork fabrication, these non-standard building components can potentially be produced in a more cost-, time- and material-efficient way. Moreover, Eggshell opens up possibilities for fabricating structurally optimized geometry, enabling a more efficient use of resources. The research builds upon previous work done as a part of an interdisciplinary master thesis in a collaboration between Gramazio Kohler Research, the Institute of Robotics and Intelligent Systems and the Physical Chemistry of Building Materials group (ETH Zurich). In the thesis a process was developed in which a thin-shell formwork is 3D printed while a fast-hydrating concrete is simultaneously fed in. By 3D printing the formwork, complex geometries can be fabricated effectively. The printed formwork can potentially also be recycled and reused, making the process fully circular. Furthermore, reinforcement can be integrated into the structures, allowing for the creation of structural building components.

The rapid growth in building stock and the demand for new construction present significant challenges in terms of material scarcity, waste production, and greenhouse gas emissions. To address these challenges, a fundamental shift in the construction industry's approach is needed, viewing waste as a resource through circularity principles. This research focuses on the application of circular principles and resource efficiency in the reuse of structural steel within the European construction industry. However, the utilization of reclaimed steel in construction projects faces significant challenges, including the condition of reclaimed elements, the need for repairs and refurbishment, unclear stakeholder responsibilities, and the absence of contractual frameworks. Communication gaps and coordination complexities further compound these challenges. Despite these obstacles, the research demonstrates that reclaimed steel can be successfully integrated into projects with proper planning, coordination, and expertise. A comprehensive analysis of existing practices and challenges, interviews with industry professionals, and literature review inform the development of a design framework and a computational tool. The proposed design workflow incorporates strategies to address the identified challenges and promote efficient steel reuse within the different project phases. Additionally, a computational tool facilitates the integration of reclaimed steel through a digital inventory and matching algorithm. The matching algorithm enables the retrieval of stock information from a digital inventory. A matching algorithm is implemented to compare the list of design elements needed for a project with the available stock list. This tool efficiently identifies possible substitutions, enabling designers and engineers to find suitable reclaimed steel sections for their projects. Lastly, the design workflow and computational tool were successfully tested through a design case study, demonstrating their effectiveness and environmental impact results to allow users to make informed design decisions. Overall, this thesis project offers valuable insights and practical solutions to advance the implementation of steel reuse in the construction industry, making a significant contribution to the field of sustainable construction.

To cope with the climate crisis, sustainable and eco-friendly buildings are a necessity. To achieve this, we need to change the way we build, this accounts as well for construction materials. For thousands of years, humans have lived in clay and timber hybrid constructions. These hybrids are made of sustainable, possibly circular, highly available and renewable materials with low embodied energy. However, the labour-intensive production makes these hybrid constructions expensive. This was, among others, one reason why modern architecture and construction looked to other, industrial and artificial building materials to satisfy our need for cheap, fast and prefabricated construction methods. The promising, traditional combination of earth and timber has barley been used for prefabricated wall components and façades, despite their huge ecological benefits. On the contrary, questionable and polluting building technologies and materials are used to increase the efficiency within the construction sector. As designers and engineers, we should start looking back into clay/timber hybrids as one solution architecture can offer as an answer to the climate crisis, despite the high labour cost of this construction type. Digitalisation might be a solution to tackle these high costs. Customized computational design, large-scale 3D-printing and file-to-factory robotic fabrication allow the automatization of certain labour-intensive production steps. It offers new perspectives on production techniques and material usage. The fourth industrial revolution could, in combination with changing legislation and CO2 taxation, lead to a revival of clay/timber hybrid buildings. These hybrids could be made of timber with a density decreased non-structural gradient material infill, such as 3D printed with clay. Exploring material mixtures, production techniques and building components results in a computational, informative workflow for customized nozzles and the building component. This allows to coordinate and customise the nozzle design according to the limitations of the material properties, the building component and the 3D printing process. But how can the density of a 3D Printed clay prefab wall component with a 6-axis robotic arm be gradually decreased? Designing a gradient material that is dense on the inside and gets increasingly lighter towards the outside could increase the efficiency by adding another function to the earthen building element. The created cavities reduce the density, the thermal conductivity and the material usage compared to a traditional solid earthen infill. To simplify the toolpath and reduce the cycle time each density class of this stepwise gradated wall system has its customized nozzle. The customization of the nozzle allows to print a complex cross-section geometry with a simplified, otherwise complex toolpath. Establishing an informative workflow between the building component design, the production tools and the material mixture should lead to a feasible design that is considering the limitations of each input category. Ideally, this approach reduces the necessary amount of adaptations before the earthen component infill can be printed. The nozzles will be customized to reduce the cycle time and shorten the toolpath by creating a gradient material at the same time. This material can be used as an infill for a hybrid wall structure.

Continued humanitarian crises have caused the amount of forcibly displaced people to increase rapidly in recent years, creating an urgent need for constructing adequate sheltering to house the displaced. Governments and international organizations attempt to accommodate the growing demands by subsidizing and mass producing temporary transitional shelters that do not always meet all the emerging needs of refugee families. Many of these settlements are planned with a temporary use in mind, however, more often than not, they end up growing and turning into more permanent parts of cities themselves. In the case of Syrian refugees, several camps were set up in Jordan as an emergency response to accommodate the displaced families, namely the Zaatari camp in 2012 and the Azraq camp in 2014, with Zaatari camp being the largest Syrian refugee camp globally. These camps have now existed for nearly a decade, which collides with the original intentions of them being temporary, and are gradually becoming more permanent. When refugees first arrive they are in need of immediate sheltering and assistance, as time goes by their needs change and evolve in order to adapt to a more long-term setting. At the current rate, refugees are occupying their substandard shelters beyond the recommended lifespan resulting in housing that is largely inadequate (3RP, 2021). Due to the rigid nature of the shelters provided to refugees, some families in the Zaatari camp, for example, have been rearranging the units provided to them in order to accommodate their specific spatial needs. These self-made rearrangements are clearly shown to have evolved over time and are becoming more intricate, showing a need for adapting and evolving the one-size-fits-all structures provided by international agencies into more customized solutions corresponding to individual family needs. Additive Manufacturing in construction is an emergent technology that has garnered the attention of many researchers and developers recently, with new developments being constantly made in the field of 3D printing buildings and building components. Researchers argue that 3D printing as a construction technique can be a valid alternative for overcoming the limits and shortcomings of typical construction methods of refugee shelters being used currently, and can fulfill the requirements of adequate housing for refugees. Earth presents itself as a construction material with various functional and environmental benefits for the construction of shelters. Moreover, earth has been widely used in buildings for thousands of years around the world and has demonstrated its ability to stand the test of time. Buildings made using earth are reusable, recyclable, and inherently biodegradable allowing vegetation to grow back into them after use leaving no waste behind (Rael, 2009). Furthermore, earth is a material that is readily available on-site in many locations needing minimal transport compared to other materials, which in combination with its other properties enables building structures with very little embodied energy (Volhard, 2016). Mass customization is inherent to the process of additive manufacturing where robots can produce customized designs in an iterative process and no two models have to be alike, which in combination with using earth found on-site as a medium for printing, could make it a viable approach to constructing shelters that would meet individual refugee family needs. This research aims to investigate the possibilities of doing so through developing a mass-customization design tool for 3d printing refugee shelters using earth.

Common Reed (Phragmites Australis) is an abundantly available, sustainable construction material that can be found throughout the world. Reed is most commonly used for thatch roofing in Europe, providing insulation and a weather-tight surface. Elsewhere, traditional techniques of weaving and bundling reeds have long been used to create entire buildings. This research develops a new alternative to these techniques with the aim of showcasing the ability of reed to perform as structure, insulation, and cladding all at once. In the Netherlands, the availability of inexpensive imported reed has led to a decline in demand for Dutch reed for thatching. This is problematic as the management of reed beds is essential for nature conservation. The research aims to promote the use of Dutch reed for construction through utilising a digital production chain in order to reduce labour costs. Through an iterative process of designing from the micro to the macro scale and by experimenting with robotic assembly, the result is a reed-based system in the form of discrete components that can be configured to create a variety of structures. The project questions permanence in architecture, through the proposal of a series of nature observation structures for the National Park Duinen van Texel. The structures are intended to last ten to twenty years and utilise completely biodegradable materials which can be disassembled whenever necessary. This semi-permanence allows for future flexibility and ensures preservation of the natural environment. Physical prototyping and testing of the proposed robotic assembly process validates the approach.

Architects and urban planners still rely on physical models in the design process, particularly for urban contexts. However, developing such models can be time-consuming and resource-intensive, despite the abundance of digital information available. This study investigates the feasibility of using pin-type models, specifically in the concept and design phase of mass modelling and analysis for urban, rural, and complex building sites. The research uses a combination of literature review, design-based research, and interviews, leading to the discovery of a promising solution. Existing pin-type models in the market or universities either come at a high cost or lack the necessary resolution to generate detailed urban models. However, this study identifies a method that significantly reduces costs while achieving higher pin resolution, although with some compromises in generation time and holding power compared to current models. The innovative rubber layer, also known as the state layer, plays a crucial role in the machine's advancements. This layer enables the machine to keep pins in place at a lower cost but with lower holding power. Additionally, leveraging technology from the 3D printing and CNC manufacturing domains, the machine incorporates multiple individually moving motors that can rapidly set up to 40 pins in one motion, reaching speeds of up to 1200 pins per minute. Making it possible to generate large pin sets in less then an hour, meaning it would be faster than traditional methods like 3D printing or manual foam cutting. Furthermore, the research emphasizes the central role of code in this study. Integrating all the necessary steps into a single code can generate an urban area within minutes. The program facilitates a user-friendly interface for selecting locations, automatically downloading height maps from the AHN (Actueel Hoogtebestand Nederland), converting the data into a digital model compatible with the machine, and exporting it as a G-code file. The machine and code also support displaying additional digital information, such as 3D models and images. Combining the improved machine and optimized code demonstrates the potential to create physical urban context models from digital data at a relatively low cost compared to other devices. With working times of minutes instead of hours or even days, compared to traditional model-making methods. Although this research shows considerable potential, there are several challenges that demand attention and additional investigation. The ultimate determination of whether the final product will require a $10,000 or $20,000 investment hinges upon the availability and cost of visible pins. Moreover, the current conversion of rotation to Bowden cables is suboptimal, and further enhancements are necessary. Additionally, the code could benefit from optimization to ensure compatibility with slower computers, thereby improving its speed and efficiency. Furthermore, the code should be extended to enhance its compatibility with 3D models, and ideally, with BIM models as well. It is essential that the code incorporates a function enabling the combination and selection of data, facilitating the movement of only the necessary sections of the machine. With this research, a solid foundation has been established for further expansion and exploration in this field. The successful development of a working machine code paves the way for practical testing and implementation. Although there are some mentioned additions that could enhance the research, the limitations of time prevented their full exploration in this study. Nonetheless, this research opens up exciting possibilities for future advancements and applications in the field.

Kinetic responsive systems are gaining attention in architectural applications, to help reduce the building’s energy consumption and environmental impact, while improving the indoor comfort conditions. The thesis explores the potentials of Shape Memory Alloys (SMAs) for the design of autoreactive facade systems without using additional energy. The exploration is conducted and assessed through the design of a facade concept for the city of Athens in Greece, aiming to improve both the indoor and outdoor environment by means of a kinetic autoreactive system, with a focus on the building’s direct and indirect impact on the Urban Heat Island (UHI) effect. The methodology follows a feedback-loop logic informed by environmental and energy performance evaluation studies conducted in the Grasshopper environment to optimize the shape, geometry and movement of the proposed shading component. Throughout the facade design development, a comprehensive and systematic computational toolset is being developed, targeted on the abovementioned performance evaluation studies with the goal to compose a combined digital tool to facilitate designers and other specialists in the area. The proposed facade system, as a case study application and outcome of this iterative process, features a dynamic seasonal response, triggered by the temperature changes and exhibits a dual function. During the cooling-dominated periods, the aim is to reduce the cooling demands, by increasing the reflective surfaces directing the incoming solar radiation to the atmosphere, while also increasing the shading and self-shading effect through undulated geometries. In the contrary, during the heating-dominated periods, the system adapts a double facade function with multiple-cavity zones for heat amplification, with a higher solar absorption enabled through larger sun exposure. The system’s mechanism composed of two SMA wires, operates in coordination with a pivot axle and rotating mechanism, in combination with elastic steel threads and membranes that can accommodate the dynamic deformations. The activation of the SMAs, due to the environmental temperature changes, causes their linear deformation and initiates with a single movement the linear and rotational movement of the components involved, in a cause-effect internal system, while also controlling the cavity aperture. The design aims to minimize the need for actuators and mechanical parts with no additional energy, while the study evaluates in parallel the energy and environmental performance in the urban microclimate and the potential for passive operation. Through the development and assessment of the facade concept, the objective is to explore the potentials and limitations for the application of autoreactive envelopes in the facade design and development. At the same time, the aim is to exploit the possibilities and optimization potentials offered through the developed iterative computational workflows. This is realized through an interoperability logic of the digital tools used for the data interchange, which can be developed and used as a toolset in a broader range of applications, with the studied facade design as one demonstration example of its use in practice.