Abstract
We present a process that revisits form-finding within digital media, namely parametric design and robotic fabrication. It is inspired by classical architectural and engineering experiments producing minimal surfaces and tensile structures by physical simulation of materials and natural forces. Fabrication is based on thermoforming, where thin sheets of amorphous PET are heat-treated and while in malleable state, where the material behaves like stretchable membrane, an industrial robot imprints a shape and sheets are rapidly cooled down assuming their final form. Key aspects of the approach include: (a) Speed: as each sheet is formed within seconds; (b) Flexibility, as a wide-range of shapes are produced without fabrication of unique dies; and (c) Resilience, as unlike traditional form-finding processes where the derived forms are ephemeral, the objects produced here are robust, they may be used directly or employed in subsequent fabrication processes. The produced sheets are used here as molds for glass-reinforced concrete casting offering excellent surface quality and the ability to create geometry unlike any conventional fabrication techniques. We present the design and development of the process and a proof-of-concept artwork produced. (C) 2018 Society for Computational Design and Engineering. Publishing Services by Elsevier.