This paper, authored by Ghang Lee and Seon Woo Kim, covers three years of research conducted to address challenges related to the mass customization of double-curved metal panels, focusing specifically on the Dongdaemun Design Plaza (DDP) building.
Abstract
Contrary to general perception, the mass customization of double-curved metal panels with minute variations remains a difficult challenge. This paper reports the results of three years of research to develop a new hybrid sheet metal processing technique for fabricating the double-curved metal panels of the Dongdaemun Design Plaza (DDP).
The DDP, designed by Zaha Hadid, features an abnormally high proportion of double-curved panels. Out of a total of 45,000 façade panels, approximately 22,000 are double-curved panels. Despite the complexity and diversity of panel types, the joint width is merely 25mm. Precision and a limited budget were key requirements.
Through trial and error, the project team succeeded in developing 'Multipoint Stretch Forming', a new economical sheet metal forming method that combines multipoint forming and stretch bending. Several machines and prototypes were custom-built and tested for this purpose. Using this new method, the fabrication cost for a typical double-curved panel was $260 per m², which was significantly lower than die casting ($7,000 per m²) or hydroforming ($3,000 per m²). Furthermore, the average fabrication time per panel was reduced from several hours to 15 minutes.
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