Teaching
ARCH509 Design Build Studio
Ultra-Thin Concrete X
Frei Otto
University of Kansas
2025 Fall
Students:
Hai Nguyen
Luke Greseth
Luke Scalise
Jackson Meers
Sponsored by:
BuildEx
This project was developed in ARCH 509 DesignBuild (Fall 2025) as an intensive investigation into ultra-thin concrete construction, informed by a study of Frei Otto’s Compass Method. The Compass Method is an algorithmic approach that translates free-form surfaces into mesh systems with equal edge lengths, offering an efficient balance between geometric rigor and structural logic. Over an eight-week period, a team of four students adopted this method as both a design framework and a construction guide.
Working under a strict material constraint, the students designed and fabricated super-thin concrete components with thicknesses approaching 1/8 inch. Through iterative prototyping, they explored how mesh geometry, repetition, and folding could enhance stiffness and stability at such minimal thicknesses. The concrete elements were cast as narrow strips with embedded metal mesh reinforcement, then folded into a zigzag configuration. These folded strips were assembled by simply stacking them together, allowing geometry and friction to play a primary role in the system’s performance.
The project culminated in a full-scale mockup that tested the feasibility of the approach. While the final installation required supplemental structural support, the mockup demonstrated that the system could function effectively even with extremely thin concrete components. The project highlights how algorithmic geometry and experimental making can push the limits of material performance.
Working under a strict material constraint, the students designed and fabricated super-thin concrete components with thicknesses approaching 1/8 inch. Through iterative prototyping, they explored how mesh geometry, repetition, and folding could enhance stiffness and stability at such minimal thicknesses. The concrete elements were cast as narrow strips with embedded metal mesh reinforcement, then folded into a zigzag configuration. These folded strips were assembled by simply stacking them together, allowing geometry and friction to play a primary role in the system’s performance.
The project culminated in a full-scale mockup that tested the feasibility of the approach. While the final installation required supplemental structural support, the mockup demonstrated that the system could function effectively even with extremely thin concrete components. The project highlights how algorithmic geometry and experimental making can push the limits of material performance.
