Manufacturing of Innovative Self-supporting Sheet-metal Structures Representing Freeform Surfaces

In the architecture and construction sector the increasing wish for individualization is often expressed in complex-shaped freeform buildings. Due to missing universal and mature construction methods, freeform buildings are usually realized using customized solutions often including material-consuming substructures, while the visible skin has neither structural nor functional properties. In this context a new concept is presented for manufacturing self-supporting lightweight freeform structures that integrates load- bearing, functional properties and façade design in one unit, using a double-layered structure. The realized prototype building demonstrates an efficient lightweight freeform structure with a surface specific weight of less than 16 kg/m2.