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By Any Means Necessary: Digitally Fabricating Architecture at Scale

Architectural manufacturing is a balancing act between production facility and a custom fabrication shop. Each project Zahner takes on is different from the last, and not likely to repeat. This means that workflows are designed and deployed for each project individually.
We present Flash Manufacturing, a fabrication methodology we employ in the production of architectural elements for cutting-edge and computationally sophisticated buildings. By remixing manufacturing techniques and production spaces we are able to meet the novel challenges posed by fabricating and assembling hundreds of thousands of unique parts. We discuss methods for producing vastly different project types and highlight two building case studies: the Cornell Tech Bloomberg Center and the Petersen Automotive Museum. With this work, we demonstrate how design creativity is no longer at odds with reliable and cost-effective building practices.
Zahner has produced hundreds of seminal buildings working with architects such as: Gehry Partners, Zaha Hadid, m0rphosis, Herzog & de Meuron, OMA, Steven Holl Architects, Studio Daniel Libeskind, Rafael Moneo, DS+R, Foster + Partners, Gensler, KPF, SANAA and many more.
This paper disrupts conventional discourse surrounding manufacturing/construction methods by discussing the realities of mass customization—how glossy architectural products are forged through ad hoc inventive engineering and risk tolerance.