Diatoma; A Robotically Fabricated Bio-Inspired Lightweight Structure

The construction industry faces major challenges in reducing material waste and enhancing fabrication efficiency, particularly in non-standard architecture. Many organic forms lack structural function, relying on heavy substructures that increase material consumption. Additionally, traditional forming methods require costly molds, making customization inefficient and environmentally unsustainable. Robotic fabrication offers new possibilities, but its adoption to real world applications are limited due to unknown material performance, complexity of techniques, costs and safety concerns. Addressing these challenges requires a new approach that is more explorative and inspired by naturewhich also integrates structural efficiency, fabrication-aware design, and material optimization from the start.

Nature has evolved solutions over 3.8billion years, optimizing material efficiency. DIATOMA draws inspiration from diatoms, microscopic algae with lightweight yet strong exoskeletons, translating their structural logic into architectural design principles. A biomimetic parametric design to robotic fabrication workflow was created, integrating fabrication and material constraints from the outset, to ensure a hollistic approach. Using Robotic Incremental Sheet Forming (RISF), thin aluminum sheets were shaped into non-standard components with minimal waste. Instead of post-fabrication corrections, the design iteratively adapted to material behavior, ensuring precision and efficiency. This holistic approach redefines architectural fabrication by seamlessly integrating design, material, andfabrication constraints.

DIATOMA is a self-supporting, biomimetic structure that combines design excellence with sustainability through resource efficiency, digital fabrication, and adaptability. Its mold-free robotic forming reduces material, cost, and labor. The nature-inspired form is visually striking and versatile. Structural analysis showed a simplified aluminum version weighs just 4kg, compared to 12kg (steel), 88 kg (timber), and 600 kg (concrete). Its lightweight, modular design enhances transportability and accessibility, especially in remote areas. DIATOMA also supports inclusive practices by empowering women in construction. Fully disassemblable and reusable, it offers long-term adaptability for temporary and permanent applications, promoting a circular, low-impact future.

Diatoma’s key innovation lies in its synthesis of biomimetic design and robotic fabrication. Inspired by the micro-structural pattern of diatoms, the form features a ribbed and porous geometry that achieves strength through minimal material use. Using RISF, the design transforms flat aluminum sheets into complex, curved components—without any molds. This results in a lightweight yet durable shell with significantly reduced environmental impact. Each of the 39 components is unique and mirrored to create upper and lower halves, which are joined using 3D-printed joint system. The joints account for fabrication tolerances, enabling quick assembly without heavy machinery or skilled labor. The structure is fully disassemblable, reusable, and transportable, making it ideal for temporary installations or deployment in remote areas. A defining feature of Diatoma is its adaptability: the system can be scaled and reshaped to meet design, fabrication and contextual needs. Whether used as an event pavilion, shelter, or prototype for space applications, it delivers architectural performance without compromising sustainability. Its process-driven design—from simulation to fabrication—demonstrates a clear and repeatable methodology that can be applied across multiple industries. By integrating material efficiency, biomimicry, structural intelligence, and advanced fabrication, DIATOMA presents a new paradigm in architecture.