Nesting Fabrication: A Pedagogical Framework for Freeform Shell Construction

This paper aims to introduce a fabrication-driven design strategy called “nesting” and to highlight its key characteristics and potential for a more sustainable future. Nesting is an innovative approach to ecological freeform shell construction, in which the shell is subdivided into nested, stackable components—resembling a set of Russian dolls—where each piece is fabricated and assembled sequentially using additive or subtractive methods. By integrating construction-aware geometric principles, it enables designers to optimize material use and fabrication time, supporting near zero-waste production. This strategy was explored through two six-credit Advanced Design Studios within the NAAB-accredited architecture program at the California College of the Arts (CCA). Studio projects included the workflow, design, and fabrication of cityTREE, a nested tower-like green biome designed to purify air. Additionally, Cocoon, a 2.9-meter-tall 3D-printed nested sculptural column, was developed to investigate the pedagogical applications of nesting in architectural education. Cocoon was subsequently fabricated at the Autodesk Technology Center in San Francisco to explore alternative approaches to freeform shell construction in practice. In this paper, after outlining the definition, logic, and characteristics of nesting strategies, the authors discuss the benefits of nesting in the education of future architects and builders, explaining its pedagogical significance.