Vault composed of 9 minimal surface modules

Project Overview

Minimal Vault explores the intersection of geometry, structure, and robotic fabrication.
The installation is a discretized stereotomic vault composed of nine curved blocks arranged along an arch that works entirely in compression.

Each block was designed by spatially replicating four Minimal Bricks - geometric units derived from minimal surfaces, characterized by zero mean curvature at every point. The form-finding process draws inspiration from the studies of Italian engineer Sergio Musmeci, who pioneered the exploration of structurally efficient minimal surfaces. When assembled, the blocks form an organic, continuous, and curvilinear spatial grid.

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Fabrication Process

The blocks were 3D printed through robotic digital fabrication using a mix of cement and marble powder.
Each block weighs 42 kg and features a single folded surface with a uniform thickness of 3.5 cm, forming a discretized yet continuous structure.

Compression tests performed on the blocks confirmed resistance up to 1000 kg, validating the efficiency and stability of the geometry.

Assembly and Structure

The vault spans 3.5 meters in length and 1 meter in width.
Construction began with the installation of two massive Apricena stone abutments, designed to absorb horizontal thrust. A temporary wooden centering was used during assembly, with the blocks laid from both ends toward the crown. Once the keystone was set, the centering was removed - leaving the structure entirely self-supporting.

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Designers: Prof. Arch. Giuseppe Fallacara, Arch. Francesco Ciriello

‍Academic Institution: Polytechnic of Bari

‍Affiliated Companies: Vertico, Stilmarmo, B&Y

‍Collaborators: Orestis Pavlidis, Jun Lee

‍Exposition: Marmomac, Verona

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