HEXASTONE

Hexastone Pavilion was developed in a collaboration between Technische Hochschule Lübeck, Vertico and Sika. The pavilion is a dome structure with a diameter of 4.5 metres, built from 102 unique interlocking stones.

Each stone was 3D-printed over a period of two days using a fully digitised production process, enabling the manufacture of a wide range of complex geometries.

The pavilion’s form was developed through a computational form-optimisation process that creates a structure working exclusively in compression. This results in a strong, material-optimised shell structure.

The project was developed according to the principle "Design for Disassembly", where the structure is designed for easy disassembly, reuse and recycling. The shell is divided into flat, hexagonal elements, enabling efficient 3D printing on a flat build platform while also simplifying the joints between the individual stones.

Unlike traditional masonry, where curved forms are created using wedge-shaped mortar joints, the curvature in Hexastone Pavilion is achieved by giving each hexagonal stone individually angled edges. This creates parallel joints between the elements and eliminates the need for traditional mortar joints.

The contact surfaces between the stones are treated with a non-adhesive layer, which prevents the transfer of tensile forces and makes the structure easier to disassemble. In this way, the project demonstrates an innovative and more circular approach to the construction of the future.