Constructing topologically optimized spatial structure using innovative mortise-and-tenon joints

Topology optimisation methods have been implemented on many architectural projects, and their design layouts always are fabricated with additive manufacturing methods due to their complex organic forms. However, there are still some difficulties that limit the application potentials of additive manufacturing in real projects, including size limitations of the fabrication devices, construction cost and transportation probabilities. Therefore, different from the conventional fabricating methods, this research achieves topologically optimized models using a subtractive manufacturing method with timber mortise-and-tenon joints from the Chinese traditional wooden tectonic system. In this paper, an initial shell model with specific plane angles is generated for Bi-directional Evolutionary Structural Optimization (BESO) due to the carpentry assemble requirements. Then, different classical mortise-and-tenon joints are selected to connect timber parts in different force-transferring paths and fabrication limitations, including plugging joints, connecting joints, and steering joints. Finally, with the convenience of on-site augmented reality (AR) assisted techniques, the lightweight timber parts can be easily assembled only by several people in an extremely short time. This project presents an effective and innovative way to achieve material efficiency and lightweight through a combination of innovative advanced tools and traditional woodworking techniques. These timber joints can be also used in architectural design in the context of Chinese traditional tectonics. The prototype pavilion is proof of the concept for the great potential in applications of on-site modular buildings, installations, and artworks.