CASTonCAST: Architectural freeform shapes from precast stackable components

Lluis Enrique, Povilas Cepaitis, Diego Ordoñez, Carlos Piles


This article introduces the CASTonCAST system for the design and production of architectural freeform shapes from precast stackable components. This system is composed of two complementary parts: a novel manufacturing technique of precast stackable building components and a new geometric method for the design of freeform shapes by means of stackable solid tiles. This paper describes both parts of the system by means of physical prototypes and geometric studies.



Casting techniques; Precast concrete; Fabrication-aware design; Architectural geometry; Architectural freeform shapes

Full Text:



CastonCast fabrication system and method. Inventors: Lluis ENRIQUE, Povilas CEPAITIS, Diego ORDOÑEZ and Carlos PILES. UK patent application GB1101013.9 (patent pending).

De LARRARD, F. Why rheology matters. Concrete International, 1999, 21(8).

DINI, E. D-Shape.

EIGENSATZ, M., et al. Panelling Architectural Freeform Surfaces. SIGGRAPH 2010, Los Angeles, July 2010.

KHOSHNEVIS, B., et al. Mega-scale fabrication by contour crafting. International journal of Industrial and System Engineering, 2006, 1(3).

LASEMI, A., XUE, D. and GU, P. Recent development in CNC machining of freeform surfaces: A state-of-the-art review. Computer-Aided Design, 2010, 42(7).

LIU, Y., et al. Geometric modelling with conical meshes and developable surfaces. ACM Trans. Graphics, 2006, 25(3).

LIM, S., et al. Fabricating construction components using layer manufacturing technology. Global Innovation in Construction Conference, Loughborough University, Leicestershire, September 2009.

LLORET, E., et al. Complex concrete structures: Merging existing techniques with digital fabrication. Computer-Aided Design, 2014.

PODOLNY, W. and MULLER, J.M., Construction and Design of Pre-stressed Concrete Segmental Bridges. New York: John Wiley & Sons, 1982.

POTTMANN, H., et al. Freeform surfaces from single curved panels. ACM Trans. Graphics, 2008, 27(3).

POTTMANN, H., et al. Geometry of multi-layer freeform structures for architecture. ACM Trans. Graphics, 2007, 26(65).

POTTMANN, H., SCHIFTNER, A. and WALLNET, J. Geometry of Architectural Freeform Structures. Internat. Math. Nachrichten, 2008.

Proceedings of the Second International Conference on Flexible Formwork. John Orr, Mark Evernden, Antony Darby and Tim Ibell (ed.). Bath: University of Bath, 2012.

PRONK, A., ROOY, I.V. and SCHINKEL, P. Double-curved surfaces using a membrane mold. IASS Symposium 2009: Evolution and trends in design, analysis and construction of shell and spatial structures. Valencia, Sept. 2009.

RAUN C. and KIRKEGAARD P.H. Adaptive mold: A cost-effective mold system linking design and manufacturing of double-curved GFRC panels. 17th international congress of GRCA-GRC, Dubai, April 2015.

SCHIPPER, H.R., Double-curved precast concrete elements: Research into technical viability of the flexible mold method. Directed by Vambersky, J.N.J.A. and Van Breugel, K. PhD dissertation. Delft University of Technology, Department of Civil Engineering and Geosciences, 2015.

SCHMIEDER, M. and MEHRTENS, P. Cladding freeform surfaces with curved metal panels: a complete digital production chain. Advances in Architectural Geometry. Wien: Springer, 2012.

THIBAUX, T., et al. Construction of an Ultra High Performance Fibre Reinforced Concrete thin shell structure over the Millau Viaduct toll-gates. 6th International RILEM Symposium on Fibre Reinforced Concretes. M. di Prisco, R. Felicetti and G.A. Plizzari (ed.). Varenna: RILEM Publications SARL, 2004.

VAUDEVILLE, B., et al. How irregular geometry and industrial process come together: a case study of the “Fondation Louis Vuitton Pour la Création”, Paris. Advances in Architectural Geometry. Wien: Springer, 2012.

Abstract Views

Metrics Loading ...

Metrics powered by PLOS ALM

Creative Commons License

This journal is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License

Universitat Politècnica de València

e-ISSN: 2341-2747    ISSN: 2341-3050