A research and development project has been conducted aiming to design and produce\nultra-thin concrete shells. In this paper, the first part of the project is described, consisting of an\ninnovative method for shape generation and the consequent production of reduced-scale models\nof the selected geometries. First, the shape generation is explained, consisting of a geometrically\nnonlinear analysis based on the Finite Element Method (FEM) to define the antifunicular of the shell�s\ndeadweight. Next, the scale model production is described, consisting of 3D printing, specifically\ndeveloped to evaluate the aesthetics and visual impact, as well as to study the aerodynamic behaviour\nof the concrete shells in a wind tunnel. The goals and constraints of the method are identified and\na step-by-step guidelines presented, aiming to be used as a reference in future studies. The printed\ngeometry is validated by high-resolution assessment achieved by photogrammetry. The results are\ncompared with the geometry computed through geometric nonlinear finite-element-based analysis,\nand no significant differences are recorded. The method is revealed to be an important tool for\nautomatic shape generation and building scale models of shells. The latter enables the performing\nof wind tunnel tests to obtain pressure coefficients, essential for structural analysis of this type\nof structures.
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