A Striking Geometric Timber Shelter at the University of Sydney

The HexBox canopy is a visually striking geometric installation that explores the relationship between digital design, structural efficiency and timber fabrication.

Developed through an academic collaboration between the University of Sydney and TU Kaiserslautern, the project demonstrates how advanced computational modelling and precision manufacturing can transform plywood into a lightweight yet structurally robust architectural form.

STRUCTAply Square Edge was selected as the primary material, enabling both structural performance and fabrication accuracy.

The Design Challenge

The canopy’s geometry was based on a funicular shell concept, a structural form that naturally responds to load within defined boundaries. Achieving this complex geometry required:

• Millimetre-level fabrication precision
• Efficient material use
• Rapid on-site assembly
• Lightweight construction without metal reinforcement

For a temporary educational installation, the structure also needed to be demountable and transportable.

The Porta Solution

STRUCTAply Square Edge formed the entire timber shell, with hollow polygonal segments cut, assembled and glued to create a self-supporting canopy without additional metal fasteners.

Using computer-controlled CNC cutting, 20 individual box modules were fabricated from standard 1531 timber segments cut from 13 plywood sheets. Advanced nesting strategies ensured minimal material waste while maintaining dimensional accuracy.

Traditional wedge joints were integrated into the system, allowing rapid on-site assembly and precise alignment. Despite its 45-square-metre footprint, the completed structure remained lightweight and capable of disassembly for relocation.

STRUCTAply Square Edge delivered:

• Structural stability without additional metal framing
• High precision suitability for digital fabrication
• Efficient sheet optimisation and reduced waste
• Lightweight yet durable performance
• Clean exposed timber finish

Sustainability & Australian Manufacturing

STRUCTAply Square Edge is manufactured at Porta using sustainably grown Australian plantation pine.

By sourcing plantation-grown timber and manufacturing locally, Porta supports responsible forestry and Australian industry. Timber used in long-life applications stores carbon for the duration of its service life, contributing to reduced embodied carbon outcomes compared with more emission-intensive materials.

Material efficiency was central to the HexBox design, aligning with the university’s sustainability objectives and reinforcing the value of renewable timber systems in architectural experimentation.

The Outcome

Installed on the terrace of the Wilkinson Building, the HexBox canopy provides students with shaded outdoor space while serving as a full-scale demonstration of digital fabrication and timber engineering.

The result is:

• A structurally efficient funicular shell
• Precision-fabricated modular components
• Rapid assembly through engineered timber joints
• Minimal material waste
• Sustainably grown Australian plantation pine
• Manufactured in Australia at Porta

The HexBox canopy illustrates how STRUCTAply Square Edge can support innovative architectural exploration, combining computational design, craftsmanship and responsible material sourcing in one cohesive system.