Parametric Driven Approach to the Production of Organic‐Shaped ETFE Cushion Structures: Case Study of the Perugia Bus Station Canopy

Abstract

ETFE cushions are a well‐established solution in contemporary lightweight architecture due to their low weight, transparency and durability, enabling large spans with minimal structural demand. Their realization requires specialized processes such as form‐finding, cutting pattern generation and coordination with fabrication constraints. While these processes can be efficiently automated for repetitive geometries, projects with a high degree of variation remain challenging. The bus station canopy in Perugia, completed in 2024, consists of 65 unique polygonal ETFE cushions, making conventional repetition strategies insufficient. A parametric‐driven workflow was therefore implemented to connect design and production. Structural software defined the inflated forms and cutting patterns, while a parametric model controlled the aluminum edge profiles and connection system. This integration of digital tools linked cushion geometry with production logic, enabling rationalization of complex geometries and improving precision, efficiency and coordination in the realization of a non‐standardized ETFE structure.