Researchers from Empa and ETH Zurich are taking inspiration from age-old Alpine shingle-making techniques to develop innovative, sustainable wood-based materials that could shape the future of construction. By optimizing the splitting of logs rather than sawing them, this new approach allows for higher material efficiency and lower environmental impact—making it a promising alternative for eco-friendly design disciplines.

From Tradition to Innovation
In Alpine regions, wooden shingles have long been hand-crafted by splitting logs rather than sawing, a method that produces naturally wedge-shaped slats with little material waste. This traditional technique not only maximizes yield from lower-quality wood but also enhances the mechanical strength of the resulting panels. By splitting along the grain, the process maintains the wood’s natural fibre integrity, creating elements better suited for load-bearing applications.

This method is being revived with the help of AI-based scanning systems and automated tools to sort and align wood segments, streamlining the production of consistent, scalable panel products. These AI systems evaluate strength and shape, helping to optimize the yield from each tree trunk—especially from those previously unsuitable for conventional sawn timber.

Circular & Biobased Material Advantages
The innovation shines in its capacity to utilise underused timber resources, including fast-growing, storm-damaged, or lower-grade trees—materials typically discarded or burned for low-value energy use. This makes it particularly appealing in circular construction practices, where resource efficiency and waste minimization are key. Additionally, it reduces reliance on slow-growing, high-quality softwoods.

The panels created through this process are envisioned for structural and non-structural use, offering potential applications in architecture, interior construction, and product design where strength and sustainability are priorities. Their biobased origin, carbon-sequestering potential, and the minimised processing energy add further ecological value.

Research Outlook
This research is part of the Minimassivwood project, under the Swiss National Research Programme “Resource Wood”. The goal is to develop robust, renewable construction materials using AI-guided production systems to better utilize local wood types, contributing to climate-friendly design and the reduction of CO₂ emissions in the building sector.

Implications for Designers
For architects and designers invested in low-impact materials and biobased innovation, this technique represents an exciting development. By elevating traditional craftsmanship with advanced technology, it opens new paths for aesthetic and structural wood applications that align with sustainability goals and future material standards.

Source: Empa (Swiss Federal Laboratories for Materials Science and Technology)
Photos: Empa