Parametric design and modular construction of a large additive-manufactured hypar shell structure

Despite recent advances in additive manufacturing technologies, challenges remain to build 3D-printed structures at the architectural scale due to the high cost of large printing equipment. To address this challenge, modular construction has demonstrated its merit by making smaller prefabricated components and using on-site assembly. This paper presents a case study of a 3D-printed hypar shell structural art using modular construction. Guided by parametric design and structural analysis, we optimized the hypar shell to form a butterfly-like shape with a hollow-out pattern. The prefabrication of modular units was completed using commercial 3D printers to catch a limited production time. The prefabricated modular unit of the hypar shell was assembled on site for the Guangzhou International Light Festival, in which the lighting effect was added through the adjustable transparency of hollow spaces within the sandwiched panels. The 3D-printed hypar shell was also disassembled and rebuilt in the UK, showcasing the adaptability and flexibility of the modular design. The resulting 3D-printed structural art not only provides unique aesthetics for the built environment but also demonstrates the possibility of building large shell structures with a low budget by reducing complex falsework.