FLAXPACK

This research project was initiated and conceptually developed at BioMat Studio, University of Stuttgart, building on prior investigations into moldless fibre composites with the goal of eliminating the need for moulds and formwork during resin curing. The project was undertaken by students Kevin Saslawsky, Christian Steixner, and Michael Tucker during the Material and Structure seminar (WS 2021/22), tutored by Vanessa Costalonga, M.Sc., and supervised by Assoc.-Prof. Dr.-Ing. Arch. Hanaa Dahy.

The concept introduced compliant folding mechanisms into flat preforms made from fibre-reinforced polymers (FRPs), enabling them to transform into programmed three-dimensional geometries without conventional shaping tools. These flat-pack components are material-efficient to produce, easy to transport in their compact form, and can be quickly assembled on-site into their intended bent-active state. The form is secured using a simple drawstring system, which can later be released to revert the component back to its flat configuration.

This research not only addressed fabrication and logistical efficiency but also demonstrated the aesthetic potential of FRP flat-pack systems, producing elegant structures in which material, form, and structure are seamlessly integrated. Following the student-led exploration, BioMat GmbH further examined the approach for its potential in scalable applications, from deployable furniture to adaptive architectural systems, where mobility, efficiency, and expressive form are equally valued.