The development of three-dimensional cladding in architecture has witnessed significant advancements, particularly from the computer-driven design era, which started to enable the creation of intricate and elaborate shapes. However, examining various case studies has revealed the considerable environmental impacts of the materials typically employed in three-dimensional cladding. These impacts include material extraction and production, energy consumption, waste generation - and further carbon emissions - underscoring the urgent need to address these challenges.

This research aims to investigate and develop a design solution rooted in circular principles for mitigating the environmental impact of the construction industry and promoting waste-driven design. To this end, bio-based materials produced through a moulding process have been identified as promising alternatives with lower environmental footprints.

The adoption of circular strategies, including modularity and flexibility, dematerialization, the use of safe and circular materials, and design for disassembly, serves as the guiding framework for enhancing sustainability in the three-dimensional cladding. As a specific design solution, the concept of seamless tiling has been developed, enabling the continuous pattern and flexible placement of modular panels within the facade while ensuring versatility. Applying parametric design techniques is instrumental in realizing the modular panel system and accentuating its adaptability by creating diverse and versatile façade configurations that exemplify the system’s adaptability and flexibility.

Finally, to validate the material’s performance within the developed design, a prototype will be constructed and evaluated. This empirical testing will provide insights into the proposed design solution’s practicality, feasibility, and effectiveness, serving as a vital step towards practical implementation.

This academic research contributes to the discourse on sustainable architectural practices by advocating using bio-based materials with moulding and integrating circular design strategies in the three-dimensional cladding. Through the comprehensive exploration of these approaches, the study aims to advance the understanding and realization of how three-dimensional architectural interventions can be developed with minimized impacts and, eventually, fostering a more sustainable built environment while maximizing design flexibility.