Reimagining construction: advanced robotic LFAM at Biennale Architettura 2025

“Domino 3.0: Generated Living Structure” designed by Kengo Kuma & Associates for the Biennale Architettura 2025, is an architectural synthesis that explores the dialogue between nature and advanced production, showing how robotic additive manufacturing technologies and organic elements can redefine the future of construction.

Caracol collaborated with the renowned Japanese architect Kengo Kuma on “Domino 3.0: Generated Living Structure”, an architectural installation showcased at the Biennale Architettura 2025, curated by Carlo Ratti. The work aimed to explore the intersection between natural materials and advanced industrial applications, highlighting the dialogue between nature and manufacturing.

Concept development
The creative inspiration behind the project originates from Storm Vaia, which ravaged the forests of northern Italy in 2018, uprooting thousands of trees. In response to this immense natural devastation, architect Kengo Kuma salvaged several of these fallen trunks, transforming them into raw materials to reinterpret the very essence of architecture. Once recovered from the forest, the logs were 3D scanned by D3 Wood to capture the unique features of their organic shapes. This digital analysis enabled the design of custom joints, turning the irregular timber into components suitable for architectural construction.

Initially, Kuma had considered using transparent PETG for the production of the joints. However, following an exploratory visit to Caracol, he was struck by the performance and flexibility of TPE – a thermoplastic elastomer which can be used for cushioning, flexible structures, or logistics applications. Impressed by its versatility, he ultimately chose this material as a more suitable alternative for the project.

Joint manufacturing: from computational design to multiplanar printing

The technical process behind the project was both complex and captivating. After selecting and 3D-scanning the logs, the resulting geometries were processed to create customized, functional intersections. The naturally irregular and complex surfaces were “translated” into printable files through a Grasshopper-based workflow, essential for generating adaptive, parametric and printable geometries. The design phases evolved as follows:

• Phase 1: Structurally similar joints focused on strength and performance
• Phase 2: Each joint was uniquely optimized, refining the design for aesthetics as well

All components were then sliced through Eidos Builder, Caracol’s software for path planning, and produced with a Heron 300 equipped with HV extruder – Caracol’s robotic LFAM platform technology – employing multiplanar printing crucial for ensuring accuracy on inclined and organic surfaces. One of the main challenges was optimizing the internal infill for the specific branch and section of the structure, which had to conform to irregular forms while ensuring mechanical performance, printability and visual quality.

Technical details:

• Technology: Heron AM 300 – HV extruder
• Material: TPE
• Nozzle size: 5 mm
• Dimensions: 400 x 650 x 700 mm
• Weights: 27 to 54 kg (based on the shape)
• Post-processing: none
• Process optimization: managing complex geometries with structural infills tailored to mechanical and design needs

Unlocking the potential of TPE in the construction industry

The adoption of 3D printed elastomers, such as TPE could be a relevant innovation for the construction industry. Although still relatively unexplored in the sector, the material demonstrated great potential:

• Adjustable flexibility: Depending on the printed section, it can be either rigid or elastic
• High printability: Ideal for complex geometries and inclined plane printing
• Extreme ductility: Unlike rigid materials, TPE doesn’t break easily, and cracks do not propagate
• Cross-sector applicability: Suitable for gaskets, seating, logistics, and shock-absorbing structures

New paradigms for the construction industry
The “Domino 3.0” installation stands as a prime example of how Heron AM and flexible materials like TPE can unlock new opportunities in the development of organic, resilient and customized structures:

• Irregular geometries can be successfully addressed and adapted for additive production
• Flexible materials, when properly engineered, can become structural elements
• Innovative production processes such as Multiplanar printing technique can overcome the limitations of traditional additive manufacturing

The installation, currently on display in Venice, Italy, remains a testament to the successful alliance between nature and technology. Originating from Biennale Architettura 2025, this vision has the potential to inspire new paradigms in the construction sector thanks to the application of LFAM technologies.

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