A new method for designing and engineering complex façades and their requirements needs to be explored and applied. This method utilizes the file-to-manufactory concept, which explores parametric design approaches and additive manufacturing opportunities.

The two are growing trends and offer new possibilities. These parametric design approaches change how planners/designers perceive building details. Therefore, a unique design and engineering concept is needed to envelop the complexity of architectural geometries. This complexity is increasing, due to the rapid developments in all related aspects, such as façade systems, modeling software, and digital manufacturing techniques.

Because of the increased complexity of architectural geometries, traditional project management is inadequate. The file-to-manufactory concept is a contemporary way to enhance architectural possibilities and maximize efficiency. This concept needs to explore specific BIM, CAD, and additive manufacturing techniques. This dissertation explores the required steps and presents them as a design and engineering concept that suits most elaborate façades and envelopes.

The design and engineering concept is divided into digital conception and manufacturing conception.

In the digital conception, CAD software defines the project’s complex geometry parametrically and generates all the digital information needed to control the manufacturing process. Through the digital conception, the primary rules of the complex façade structure are defined into categories such as connection type and joining system.

Additive manufacturing or 3D-printing is one of the computer-aided production techniques utilized for manufacturing. Therefore, this process is investigated and tested to check its suitability for the façade industry.