151-TRK
Toorak 

Next Project
This project entailed the design and implementation of a 300 m² bowl-shaped roof for a private residence in Melbourne, designed by Wood Marsh Architects. The roof structure comprises over 1,800 diamond-shaped zinc elements, necessitating precise detailing and an efficient system for fabrication and assembly. Our task was to develop the system for the folded zinc shingles and the plywood substructure, along with generating the corresponding manufacturing data, all within an eight-week timeframe.

The roof’s double curvature and elliptical plan necessitated unique geometries for each component, with all elements fabricated off-site. Panels were precision-cut, folded, and assembled on-site with tolerances under 2 mm, while the plywood substructure was engineered to deform locally to accommodate the complex surface profile. Core aspects of the project included geometry simplification, reduction in unique part counts, and the development of a robust system for part categorization and labeling. Through close collaboration with the client and architectural team, a parametric 3D model was created, integrating material, production, and construction constraints. This model yielded over 2,300 detailed shop drawings and produced automated documentation for both in-factory and on-site coordination, along with CNC-ready files for efficient production and assembly.
Project    
Client      
Formation
Services
Typology
Partners
Location
Status
Year      
Toorak
Craft Metals Australia
Vorhammer at AR-MA
Design to Fabrication
Architecture
Wood Marsh Architects
Victoria (AU)
Completed
2015