Introducing Tailored Fiber Placement (TFP) as a Sustainable Fabrication Method for Architecture: Four Case Studies in Mold-Less and Integrative Construction

The urgent need for sustainable innovation in the construction industry necessitates a reevaluation of how architecture engages with materials and fabrication processes. This paper introduces tailored fiber placement (TFP) as a novel fabrication method with significant potential for advancing sustainable architectural practice. Originally developed for aerospace and automotive applications, TFP enables stress-oriented fiber alignment, offering precision, material efficiency, and lifecycle-conscious design opportunities. To articulate these capabilities, the paper examines four case studies at multiple scales. Ranging from small-scale seating to medium-scale façade components, these examples demonstrate TFP’s ability to enable mold-less forming and integrative fabrication in support of sustainable construction. Through digitally programmed fiber orientations, the cases achieve both structural and geometric requirements while minimizing waste and improving workflow efficiency. This research positions TFP as a material-aware and performance-driven approach to sustainable architectural production. By bridging material, design, and fabrication, TFP contributes to more circular, adaptable, and efficient construction systems.