Robotic Forming Enables Modular Aluminium Lighting

Digital fabrication offers new ways to shape metal without conventional tooling. Hikarigami, a student project by the Harvard Graduate School of Design, won the Sustainability category at the 2026 Core77 Design Awards. The project combines computational design with robotic manufacturing to transform flat aluminium sheets into three-dimensional structures. The approach may be relevant for architecture, interiors and lighting.

Translating Kirigami into Metal

The name Hikarigami combines the Japanese words hikari (light) and kirigami, the traditional art of cutting and folding paper into three-dimensional forms. Instead of paper, the project applies similar principles to aluminium sheet. Laser-cut patterns and robotic forming create a textured surface that filters and diffuses light.

The luminaire consists of six identical aluminium panels. Each panel starts as a flat sheet. A laser cuts a variable lattice pattern into the material. This pattern controls how the aluminium expands during forming and determines the final geometry.

Combining Parametric Design and Robotic Fabrication

The production process combines parametric design with automated manufacturing. The designers first model standard aluminium sheets in Rhino. Next, the programme Grasshopper generates a variable lattice pattern. The same digital model controls both the laser cutting and the robotic forming process.

An ABB IRB 140 robotic arm reshapes each laser-cut sheet through a series of programmed presses. A custom 3D printed PLA end-effector applies pressure without damaging the aluminium surface. At the same time, a custom wooden fixture supports the material and leaves space for each lattice cell to expand.

The project uses 3105-H24 aluminium because it combines ductility with rigidity. The robot adjusts the depth of every press to match the size of each lattice cell. As a result, the sheet forms complex curves while remaining within the material’s structural limits.

Mono-Material Construction

The luminaire uses six identical aluminium panels that interlock with integrated tabs. This design removes the need for adhesives or mechanical fasteners. Because the structure consists entirely of aluminium, it remains a mono-material product that can be recycled at the end of its service life.

The modular design also allows different configurations. The prototype forms a hexagonal tower. However, users can create other shapes by changing the number or orientation of the panels without altering the individual components.

An Alternative Manufacturing Method

Traditional sheet-metal forming often depends on custom moulds and dies. These require additional material, energy and manufacturing resources. Hikarigami replaces much of this tooling with a programmable robotic workflow. As a result, the same production setup can produce different geometries with fewer dedicated tools.

A tubular LED filament sits in the centre of the structure. The expanded aluminium surface contains thousands of openings that shape the distribution of light and shadow. Through its combination of parametric design, robotic forming and mono-material construction, Hikarigami presents an alternative approach to manufacturing customised aluminium components.

Source & photos: Core77 Design Awards / Harvard Graduate School of Design