NEGAR KALANTAR

3D Nesting | Minimum Waste Construction

—PROCESS

Data-Driven Design e

Seashell-Inspired Robotic Fabrication

Robotic Light Visualization

Clay++ | 3D Printing on Arbitrary Surfaces

Robotic Clay Printing

Non-Planar Robotic Printing


—BEHAVIOR

Tunable Smart Materials

Reconfigurable Kerf Structures

Flexible Textile

3D-Printed Flexible yet Rigid Textile

Self-Forming 3D Printed Structures

a2o | Responsive Mediator

—MATTER

Algorithmic Kerfing

BioMaterial | BacTerra

BioMaterial | Shell We Dance

BioMaterial |ShoreThing

—GEOMETRY

Nested Vault

2D Nesting

2.5D Nesting

3D Nesting

PRINT in PRINT

Casting on Sand

Folding Unfoldable

Kinetic Shading Structures

Deployable Structures

Deployable Domes

D-Form

3D Nesting

Minimum Waste Construction

2020-2022 | transLAB, Advanced Studio: Embedded Intelligence & CCA Digital Craft Lab, San Francisco.

Collaborators: Borhani

Links: Nesting Fabrication

Interlocking Shell

Research Description: 3D Nesting Method

The 3D nesting method is a fabrication strategy that divides complex volumes into stackable, interlocking components. Using non-parallel slicing planes, it produces wedge-shaped or voussoir-like elements that fit together tightly, improving both structural integrity and packing efficiency.

Unlike 2D or 2.5D methods, 3D nesting allows for more complex geometries by adapting slicing planes—twisted, slanted, or rotated—to match the form. This makes it possible to nest components of varying shapes into compact stacks for easier transport and assembly.

The method requires careful coordination of geometry, material behavior, and tool compatibility. When designed effectively, 3D nesting supports modular, large-scale construction with minimal waste and maximum spatial efficiency.