The Expandable Surface System is an architectural material system developed as part of the Emergent Technologies and Design MSc programme at the Architectural Association in London. It investigates the potential of plywood sheets to form doubly curved, self-structuring surfaces through controlled incision patterns. By applying computationally generated cut strategies to planar sheets, the system enables expansion and three-dimensional deformation, resulting in geometrically complex and structurally stable forms.
At its core, the research establishes a direct relationship between surface curvature and pattern geometry. The deformation behaviour is controlled parametrically, enabling local and global form generation through a unified set of geometric rules. The process links digital surface modelling with fabrication constraints, allowing material intelligence and performance to guide design.
The system was rigorously tested at multiple scales. A self-supporting wall was constructed for the Emergent Technologies and Design end-of-year exhibition at the AA, demonstrating the system’s ability to perform as a vertical surface. A larger-scale prototype—a four-metre-span enclosure—was deployed at an international design fair in Cologne, validating its spatial and structural capacities in inhabitable settings.
The research draws inspiration from biological systems, in which form, material, and structure operate as an integrated whole. It departs from conventional surface design by embedding logic into the material itself, thereby enabling fabrication without moulds or scaffolding. This work contributes to ongoing dialogues on digital fabrication, morphogenetic design, and low-tech deployable systems, proposing a performative alternative to conventional cladding and enclosure methods.
