FIBRFOLDR

This design project was initiated and conceptually developed at BioMat Studio, University of Stuttgart, with a focus on eliminating time-intensive formwork preparation and traditional lamination processes in the context of mass customization. The initial research and prototyping were carried out by students Okan Basnak, Maximilian Klammer, and Gabriel Rihaczek, with support from Benjamin Grisin (IFB, University of Stuttgart), during the Material and Structure design studio (WS 2019/20), tutored by Jan Petrš and Evgenia Spyridonos, and supervised by Assoc.-Prof. Dr.-Ing. Arch. Hanaa Dahy.

The concept centred on producing a flat reinforcement preform using tailored fibre placement (TFP) technology with flax rovings, precisely programmed to fold into a three-dimensional structure with minimal or no scaffolding. By integrating parametric design tools for global form-finding and tool-path generation with CNC-based fabrication, the project demonstrated the potential to mass-customize reinforcement layouts efficiently. This approach enables the creation of a wide variety of unique spatial models without increasing production effort.

The advantages of this design and fabrication system were validated through the construction of a stool prototype, showcasing both structural integrity and aesthetic potential. Following the student-led development, BioMat GmbH further advanced the concept, refining the fabrication workflow and evaluating its applicability in larger-scale architectural and product design contexts. The project highlights the transformative potential of TFP in producing high-performance, customized fibre-reinforced components with reduced material waste and fabrication time.