Desert Tectonics

3D Printed Shading System

This research develops a 3D-printed shading façade inspired by desert dunes and traditional Arab screens, optimised through computational design and material testing for lightweight, modular, and identity-driven temporary architecture.

Summary

The project presents a 3D-printed façade system designed for a service pavilion at Expo 2020 Dubai, with potential for replication in other temporary or overlay structures. Responding to Expo requirements—lightness, modularity, flexibility, and cultural identity—the façade draws inspiration from local desert winds and ornamental screens used for shading and privacy. Using computational design algorithms, the system defines a pattern of variable porosity, curvature, and thickness, optimised for additive manufacturing. Extensive material and climatic testing was conducted at Politecnico di Milano to ensure high-temperature performance. The research combines digital aesthetics, fabrication efficiency, and cultural narrative in a scalable design solution.

This research presents the development of a 3D-printed shading façade for a service pavilion at Expo 2020 Dubai, with a design approach focused on replicability and adaptability for other temporary or overlay spaces.

The project responds to the core requirements of Expo architecture:
  • Lightweight construction for ease of transport and on-site assembly
  • Modular design for rapid, scalable production
  • Functional flexibility, able to adapt to various spatial or technical constraints
  • Cultural identity, reflecting the hosting country’s heritage

The concept draws from the natural landscape and local architectural traditions. The façade pattern is inspired by the wind-driven formations of desert dunes, as well as by traditional mashrabiya screens, which filter light and preserve privacy through ornament.

Using parametric design tools, the team developed a system of curved geometries with graded porosity and thickness. These parameters can be manipulated in real-time via a Grasshopper interface, allowing for precise control of the design intent.

To translate this vision into built form, the concept was optimised for additive manufacturing. Several tests on polymeric printable materials were conducted in the Material Testing Laboratory (LPM) at Politecnico di Milano, including thermal ageing in a climatic chamber, to ensure durability in high-temperature desert conditions.

Parallel to material validation, a digital fabrication testing campaign was launched to refine both the shape of the façade modules and printing parameters—such as layer height, speed, and retraction values—for large-scale production using WASP technologies.

This project represents a convergence of design computation, material science, and sustainable fabrication, offering a scalable, expressive, and technically sound solution for temporary architecture in extreme climates.

SCIENTIFIC COORDINATOR

Giulia Grassi

TEAM

Renaud Denhaive (PhD Candidate, MIT), Sonia Lupica Spagnolo (Associate professor, Politecnico di Milano), Lapo Naldoni (R&D Department, WASP)

PARTNERS

WASP Massa Lombarda, Laboratorio Prove Materiali (LPM) Politecnico di Milano

RELATED PUBLICATIONS
☒


Associated researches

Contemporary Material and Technological Culture

Modern Method of Construction

Examines flexible and decentralized production systems that support customization through digital design and adaptive manufacturing. The main concepts of mass customisation, supply chain management and distributed manufacturing are linked together to optimize material use, environmental impact and prefabrication in architectural design.|