Manufacturing | Formwork - Automating Vertical Formwork Design with Recursive Subdivision
We engineered a sophisticated multi-stage solver utilizing a headless Rhino.Inside.Revit backend to overcome the topological complexity of vertical formwork. By implementing recursive surface subdivision and face chaining (grouping) algorithms, the tool dynamically selects and packs components from a library of over 650 types, enforcing wall-tie alignment across opposing surfaces.
- Client
- MFE Formwork
- Timeline
- 2020 - 2022
- Service
- Custom Applications→
The Engineering Challenge
While ceiling formwork (Deck) is complex, vertical formwork (Walls) presents a harder topological challenge. MFE Formwork's design team had to manually layout panels for thousands of vertical surfaces - walls, columns, beam sides, and drop slabs - while adhering to a critical structural constraint: Panel Alignment.
Panels on opposite sides of a wall must align perfectly to allow wall ties (structural rods) to pass through. If an obstruction on one side forces a panel size change, the other side must mirror it, regardless of its own geometry. Standard algorithmic approaches failed here because they treated surfaces in isolation. MFE needed a solver that understood the relationship between opposing faces.
The Solution Architecture
We engineered the Wall Solver, a companion to our Deck Formwork Automation tool, utilizing the same pioneering Headless Rhino.Inside architecture. It transforms MFE's most complex manual workflow into a single-click operation.
Face Data Chaining (The Alignment Engine)
To solve the alignment problem, we developed a Face Data Chain algorithm.
- Topological Pairing: Instead of solving walls individually, the system scans the model to pair opposing faces that fall within the wall-tie threshold.
- Unified Solving: Once paired, the solver treats the wall as a single volumetric entity. It computes a "panel width domain" that satisfies the constraints of both sides simultaneously, ensuring wall ties always align.
Recursive Subdivision
Rectilinear walls are simple, but real-world concrete cores have complex returns, kickers, and projections.
- Convex Corner Slicing: We implemented a recursive subdivision algorithm that slices non-rectangular surfaces at every convex corner.
- Fitness Tree: The solver generates multiple potential subdivision strategies and uses a fitness function to select the solution that produces the most square (and therefore most packable) bins.
Modular Feature Solvers
Vertical geometry is full of interruptions: Windows, Doors, and Projections (extruded fenestrations).
- Context-Aware: We built dedicated sub-solvers for each feature type. The Window Solver identifies jambs and sills, applying specific MFE opening components, while the Projection Solver handles the cantilevered geometry of extruded window hoods.
- Multi-Phase Execution: The solver runs in passes - first solving the primary panels, then evaluating vertical corners for adjustments, and finally aligning soffits to match the modified corners.
The Result
The tool reduced a multi-day engineering task to a 60-second background process.
- Massive Scale: It handles over 650 component types, automatically selecting the correct panel for walls, beams, and openings.
- Intelligent Output: The solver output is not just geometry; it is a valid engineering solution that respects wall-tie alignment, balance panel minimums, and structural prop positions.
- Zero Setup: Unlike manual drafting, the user simply clicks "Generate Formwork". The tool handles all surface extraction, alignment, and packing automatically.
- 650+
- Component Types Managed
- 60s Max
- Max Solve Time (vs hours/Days Manual)
- 100%
- Wall-Tie Alignment Accuracy
- Recursive
- Subdivision Algorithm