The Illuminati thesis project examined a new digital fabrication method for steel components, called Steel-GelCasting in FFFprinted formwork (SGM), from the lens of architectural design. This fabrication method is based on a recent material invention. The promise of this straightforward method is that the design and fabrication of custom, bespoke steel components at an architectural scale is not constrained by known limiting factors related to direct 3D printing or foundry casting and that theimpact of production is significantly lower.

I was interested in informing the generative design with the explored fabrication constrains while discovering the aesthetic and functional possibilities. The project discovers and demonstrates the potential of the investigated method in a multi-functional prototypical steel component, serving as structural connection, integrated lightning and ornament. An entire manufacturing chain was developed and tested iteratively from the parametric model shaping through the formwork generation and 3D printing to the final steel gel-casting.

The result of the thesis is a prototypical steel component, which is a combination of a functional element and a sculptural object, inspired and informed by the manufacturing method. The thesis also discusses strategies for computational design and digital fabrication of formworks, compares the investiageted method with other steel fabrication methods, and suggests next steps.

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