Integrated Thermal and Fabrication Workflow for Structural Frameless Glass Structures

Abstract

For more than two decades, glass shell structures have shaped architecture for their transparency and strength, traditionally using steel lattices with non-load-bearing glass. This project explores fully glass-based envelopes without conventional profiles, pushing the limits of transparent structural design while targeting material efficiency and CO₂ reduction. It investigates frameless constructions with laminated steel fittings between panes, enabling glass as a load-bearing, thermally effective envelope. Methods combine thermal simulations, structural detailing, and parametric automation. A novel linear fitting system for insulating glass was refined through iterative prototyping, laser welding, and tolerance strategies. Fabrication challenges—especially welding inconsistencies—underscored the need for tighter design-manufacturing coordination. Thermal simulations across five climate zones informed a custom visual programming tool for interactive temperature analysis and design guidance. The parametric workflow automates geometry, fabrication data, and assembly logic for applications from façades to yacht canopies. A full-scale Glasstec 2024 mock-up demonstrated both potential and fabrication sensitivity, highlighting the importance of iterative, feedback-driven development in frameless glass architecture.