Computational design and fabrication of reusable multi-tangent bar structures

• Published in: Computer aided design Vol. 188; p. 103907
• Main Authors: Huang, Yijiang, Wang, Ziqi, Hung, Yi-Hsiu, Jiang, Chenming, Gheyselinck, Aurèle L., Coros, Stelian
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.11.2025
• Subjects: Assembly; Computational design; Joints; Kit of parts; Mixed reality; Multi-tangent; Reuse; Space frames; Space frames; Mixed reality; Reuse; Computational design; Multi-tangent; Joints; Kit of parts; Assembly
• ISSN: 0010-4485
• DOI: 10.1016/j.cad.2025.103907

Temporary bar structures made of reusable standardized components are widely used in construction, events, and exhibitions. They are economical, easy to assemble, and can be disassembled and reused in various structural arrangements for various purposes. However, existing reusable temporary structures are either limited to modular yet repetitive designs or require bespoke components, which restricts their reuse potential. Instead of designing bespoke kit of parts for limited reuse, this paper investigates how to design and build diverse freeform structures from one homogeneous kit of parts. We propose a computational framework to generate multi-tangent bar structures, a widely used jointing system, which allows bars to be joined at any point along their length with standard connectors. We present a mathematical formulation and a numerical scheme to optimize the bar spatial positions and contact assignment simultaneously, while ensuring that the constraints of tangency, collision, joint connectivity, and bar length are satisfied. Together with simulated case studies, we present two physical prototypes that reuse the same kit of parts using an augmented reality-guided assembly workflow. •Computational design of diverse freeform structures from uniform kit of parts.•Modeling of tangency, collision, connectivity, and bar-length constraints.•Simultaneous optimization of geometry and connectors for uniform bars and couplers.•Augmented reality-assisted rapid prefabrication and on-site assembly process.•Two pavilion-scale prototypes demonstrate reusability of one parts kit.