Digital design and fabrication of adaptive metal nodes for timber space frame structures

This study proposes a new approach to sustainable timber construction, focusing on repurposing leftover round timber for the construction of space frame structures. It introduces digitally designed and fabricated modular metal nodes as connectors, and, as such, addresses timber shortages amid Europe's increasing timber construction sector. Central to this approach is the enhancement and optimization of wood resources, and the development of a corresponding connection technique, being suitable for nonstandard material systems, while, at the same time, emphasizing architectural simplicity and structural efficiency. The connection technique and respective connectors need to be geometrically versatile while ensuring optimal architectural and structural performance. This paper explores the design, development, and fabrication of (metal) node connectors optimized for round, leftover timber elements, considering two variants: individually topology optimized nodes produced via lost-foam casting, and a modular approach facilitating efficient assembly, mechanical adaptability, and serial production. The research framework encompasses defining parameters, detailing the iterative design and fabrication process, and presenting a 1:1 architectural prototype. Through this framework, the study demonstrates integrating leftover timber into digital design and fabrication practices, reshaping sustainable timber construction and potentially expanding the art of structural design.