Parametric Design and Mould-Based Experimental Replication of Customizable Surface Components for Industrialized Construction

The increasing industrialization of construction requires design strategies that reconcile productive repeatability with architectural customization, functional differentiation and material reproducibility. This study proposes a manufacturing-oriented parametric design framework for customizable surface components in industrialized construction. Geometry is treated as an active design variable capable of supporting hypotheses related to drainage, texture, porosity, friction, light filtering and material efficiency. The methodology links biomimetic abstraction, parametric modelling and material transfer through indirect additive manufacturing, mould fabrication and mineral-based replication. Rather than validating a specific functional performance, the study experimentally assesses a mould-based replication workflow in which customization is defined as controlled variation within a constrained design space. A modular component with a stable perimeter and parametrizable textured surface was developed, followed by the production of an additively manufactured master, a negative mould and replicas made from technical plaster and fine mineral mortar as construction-grade surrogate materials. These materials enabled the evaluation of mould filling, demoulding, defect transfer and surface-detail preservation before introducing ceramic drying and firing. The results confirm the feasibility of the proposed workflow and identify manufacturability, demoulding, dimensional deviation, material selection and application-specific validation as critical design constraints.