Inventory Informed Computational Design Method for Upcycling Cross-Laminated Timber Leftovers into Floor Slabs

Advances in digital methods enable automated design processes with non-uniform materials, promoting an inventory-informed workflow that prevents reclaimed material from being downcycled. This research explores computational design methods for upcycling rectangular cross-laminated timber cutoffs into free-form floor slabs, accounting for varying dimensions and thicknesses. It examines how altering object combinations affects the target design’s visual appeal and seam patterns using inventory-informed slicing and adaptive nesting. The slicing process transforms a 3D target design into 2D nesting boundaries with varied layer heights determined by stock availability. The metaheuristic-aided nesting then optimizes leftover combinations to maximize material efficiency, minimize cutting length, and object count. Key challenges include optimizing upcycle logistics across different inventory sizes, finding optimal nesting patterns, and balancing environmental and economic factors. As a proof of concept, case studies configured three 3-m by 6-m slabs from inventories with 50, 100, and 150 leftovers of varying thicknesses, achieving over 60% material efficiency and 30% cutting length reduction compared to new materials. This method can optimize material usage among various target designs and inventory sizes in contrast to heuristic methods. Although focused on cross-laminated timber, this computational framework applies to various planar materials, potentially enhancing circular design principles.