A team of students at the Technical University of Munich (TUM), consisting of Dimi Ale, Hyeonji Kim, Peter Hartenstein, and under the guidance of the Professorship of Digital Fabrication led by Prof. Kathrin Dörfler, has developed an innovative façade system that reinterprets Jugendstil (Art Nouveau) architecture using advanced 3D printing techniques. Designed for a residential building near the historic Altes Hallenbad in Heidelberg, Germany, the project merges heritage aesthetics with high-performance, sustainable design.

A Multi-Functional Façade Concept
The façade is conceived as a multifunctional system that integrates thermal insulation, structural integrity, shading, and decorative expression into a single architectural element. Each block within the system is digitally customised to its specific position on the façade, demonstrating the potential of computational design and mass customisation in architecture. The project is particularly relevant to architects, interior designers, and product designers exploring sustainable material applications and digital fabrication.

Optimised for Performance
The thermal performance of the façade is enhanced by a hexagonal grid structure, which is optimised using finite element and thermal simulations (FEM/FEA and HTflux). This configuration not only improves insulation but also contributes to a lightweight construction. Structural efficiency is achieved by aligning material distribution along calculated stress lines, reducing material usage while maintaining strength.

Shading and Aesthetic Expression
The design incorporates sun-shading functionality through the use of NURBS modelling and Subdivision surfaces, generating organic, flowing geometries that echo Jugendstil motifs while improving solar performance. These sculptural elements serve both visual and functional roles, contributing to a dynamic façade appearance.

Precision Assembly
Each façade block is designed to interlock via a distinctive wave-like pattern, allowing for accurate, error-free installation. This thoughtful approach to assembly minimises the risk of misalignment and simplifies the construction process, offering a practical advantage for on-site application.

Sustainable Fabrication and Material Innovation
A key innovation lies in the use of Selective Paste Intrusion (SPI), a fabrication method developed at TUM that employs concrete as the printing material. The concrete mix includes recycled glass granulate, aligning the project with goals of material circularity and resource efficiency. This not only reduces the environmental footprint of the façade system but also demonstrates how traditional building materials can be reimagined for contemporary, sustainable applications. Prototypes were fabricated in collaboration with the robotic manufacturing specialists at Additive Tectonics.

Reviving the Past with Future-Focused Tools
The project exemplifies how digital tools, parametric design, and sustainable materials can breathe new life into historic architectural languages. By merging artistry with performance and material responsibility, the students behind this façade system offer a compelling vision for the future of architectural surfaces. Their work underscores the role of innovation in addressing both aesthetic and environmental challenges in the built environment.

Source & images: Technical University of Munich, Professorship of Digital Fabrication