This project revisits traditional metal-casting techniques through the lens of digital fabrication, exploring how aluminum can be cast into highly complex geometries using 3D-printed sand molds. Custom molds are produced with Binder Jetting technology, enabling precise, detailed forms that would be prohibitively labor-intensive to fabricate by conventional means. The resulting cast components serve as structural joints that connect off-the-shelf aluminum rods into a three-dimensional space frame.

The joint design establishes a “bone-like” geometry around each node, allowing rods to extend slightly beyond their insertion points to simplify assembly. Each node incorporates at least three intersecting rod connections, ensuring stability and stiffness within the overall structural system. A custom mesh subdivision script generates the ornamental surface articulation of the cast pieces, merging structural logic with a rich sculptural expression.

These intricate nodes exemplify the visual and spatial potential of digitally fabricated metal casting. By automating mold fabrication through computational design and Binder Jetting, the project enables the production of non-standard, highly differentiated connections that were previously impractical at scale. The resulting assembly defines a unique architectural language in which form, fabrication, and assembly are tightly integrated within a computational workflow.