Knitting Shells: Reimagining Oyster Shell Construction with Digital Fabrication
Qingru Yang, Taubman College of Architecture + Urban Planning
Collaborators: Sean Ahlquist, Associate Professor, Taubman College; Glenn Wilcox, Associate Professor, Taubman College; Po-Chun Chou, Taubman College of Architecture + Urban Planning
Oyster shells, valued for their durability and insulation in coastal architecture, pose challenges due to their irregular shapes and labor-intensive installation. This project reimagines these shells within a knitted textile framework, blending material studies with parametric design. Utilizing CNC knitting machines and KUKA robotic arms, we upcycle non-standard materials to create flexible, lightweight, and light-transmitting façades.
The project delivers (i) a series of façade prototypes showcasing structural innovation, (ii) a computational knitting design tool for the creative and architectural community, and (iii) video documentation of traditional human craftsmanship with natural materials, captured through site visits and historical research.
The project begins by designing manual knitting prototypes, drawing inspiration from textile artists in the fashion industry. These prototypes explore pleated structures capable of securely holding irregular objects like oyster shells in place. Various yarns — such as copper wire, fishing line, and aggregate yarns — are tested to create elastic yet supportive structures. These yarn and stitch combinations are selected to ensure the tensile system can maintain stability under the load of the shells.
The manual process is then translated to CNC knitting machines, using a workflow that integrates 3D scanning and parametric design. Oyster shells are scanned and categorized based on size, curvature, and mechanical properties. After preprocessing, the scanned models are converted into digital bitmap representations. These bitmaps are programmed into a CNC knitting machine (3 Stoll V-bed), which produces pleated, 3D-knitted structures that precisely fit and stabilize each shell. A parametric design tool will be developed to automate this process, converting 3D-scanned objects into programmable knit structures.
To further streamline the process, KUKA robotic arms are employed for shell placement. This automation, combined with parametric modeling, enables scalability from smaller mock-ups to full-scale architectural installations. We construct prototypes at multiple scales to assess: assembly efficiency and stability. Based on each prototype’s performance, we adjust both the knitted patterns and the overall shell layout.
The project aims to increase public awareness of sustainable material reuse and foster dialogue about traditional crafts across cultures. Documentation of the research and development process will include historical and technical information on oyster shell practices, such as oyster houses in Southeast Asia and Florida’s tabby concrete tradition (Places Journal, 2022).
Site visits, annotated photos, and interviews will capture both the cultural and practical dimensions of these techniques, with discussions on topics such as craftsmanship, labor, and carbon footprint. This documentation will serve as a narrative bridge between heritage and innovation in architectural practices.
Integrating computational design with traditional materials, such as oyster shells, and techniques like knitting, will yield new artistic expressions and design aesthetics that are both culturally resonant and innovative. This project explores a methodology for combining local, non-standard materials with flexible, adaptable structures. By redefining waste as a creative resource, the project aims to develop adaptive architectural systems that balance material efficiency, cultural heritage, and environmental responsiveness.
Timeframe
February to March 2025: Initial Research and Manual Prototype Development
April to May 2025: Translation to CNC Knitting and Parametric Tool Development and Site Visits
June to September 2025: Prototype Development and Refinement
October 2025: Final Calibration and System Testing
November 2025: Documentation and Public Presentation
The project will be conducted in the Digital Fabrication and Robotics Lab (FABLab) and the CNC Knitting Lab at Taubman College, with early prototypes developed using my personal manual knitting machines.