Computational Tessellation of Freeform, Cut-Stone Vaults

Contemporary innovations in structural form-finding and fabrication techniques are leading to design of freeform masonry architecture. These new forms create new challenges in laying out tessellation patterns, especially if structural, fabrication and construction requirements as well as aesthetical considerations are taken into account. Addressing these challenges, we review historic stone-cutting strategies and their geometric principles, forming the base for the development of two new discretisation approaches for given thrust surfaces, allowing for various degrees of user control. First, we introduce a tessellation approach based on primal, anisotropic triangular meshes and their dual counterparts. Second, an alternative tessellation approach based on transverse cutting curves is presented. Using a simple set of geometric rules, both methods enable the design of rigid, staggered bonds with locally force-flow aligned block configurations to avoid sliding failures. For this research, the tessellation design of the Armadillo Vault, an unreinforced, dry-assembled, cut-stone stone shell, served as a case study to demonstrate the feasibility of our methods in the context of a full-scale architectural project.