Timber Technology:Computational Design and the DfMA Process

Theca Timber recently spoke with long-term partners and computational design experts at ENCODE – Design and Technology to discuss how computational design (CD) and Design for Manufacture and Assembly (DfMA) are helping deliver sustainable timber buildings across the country. By leveraging CD and DfMA, Theca Timber’s clients are delivering complex timber structures while maximising efficiency and construction speed. Director of ENCODE – Design and Technology, Massimiliano Manno, explains:

“Computational Design enables fast iterative design and optioneering, but its true value becomes crucial when navigating the highly constrained, ‘multi-objective’ design space of engineering, manufacturing, and construction.”

Computational Design (CD) – What Is It?

Computational design is a smart, data-driven approach to building design and engineering. By using algorithms and custom code, computational designers can create, analyse, and optimise buildings in ways that go far beyond traditional drawing and modelling methods. Instead of manually creating digital models and calculating every element, computational designers harness specialised software to:

- Explore thousands of possibilities,
- Automate complex tasks,
- Enrich building models with valuable data.

For engineered timber buildings, this approach is a game-changer. Massimiliano expands:

“Engineered Timber solutions highly benefit from computational design due to the inherent ‘digital’ nature of the material, which allows a high degree of design customisation and fine-grain control.”

By running simulations and refining designs for strength, weight, assembly speed, and environmental impact, CD helps ensure that every piece of timber is used to its full potential.

Design for Manufacture and Assembly (DfMA) – What Is It?

DfMA is an approach where architects and engineers design buildings with manufacturing and on-site assembly in mind. Rather than treating design and construction as separate stages, DfMA considers how building elements will be fabricated in a factory, transported efficiently, and assembled seamlessly on-site. This method ensures greater precision, reduces waste, and improves build times! Engineered timber—such as glued-laminated timber (GLT) beams and columns and cross-laminated timber (CLT) panels — are particularly well-suited to DfMA. Engineered Timber is manufactured to exact specifications, allowing for a high degree of customisation while maintaining mm perfect accuracy. Massimiliano details:

“The DfMA processes augmented by CD allow the whole team to design, develop, and deliver with increased awareness and control, ultimately building better and reducing costs.”

By integrating DfMA principles with CD skills, projects benefit from streamlined production, faster construction timelines, and fewer on-site complications.

Computational Design and DfMA in Action

The real impact of CD and DfMA can be seen in Theca Timber and ENCODE – Design and Technology’s collaboration on the Tumbalong Green Stage Upgrade in Sydney’s Darling Harbour. Designed by Hassell in partnership with TTW and delivered by Kane Construction, this striking diagrid timber shell provides a flexible venue for live concerts, performances, festivals, and community events.

The project’s complexity made it an ideal candidate for the CD / DfMA approach. The structure has 314 unique GLT beams, each with precise variations in shape, angles, and connections, along with 1,298 bespoke steel plates. To ensure seamless manufacturing and assembly, Theca Timber and ENCODE – Design and Technology worked together to create a fully coordinated digital model, allowing for precise prefabrication, efficient transportation, and rapid on-site assembly. Federico describes the role of the detailed LOD 450 model:

“The model represents the unique source of truth of a given project, acting as the digital repository for all key information. By aligning geometry and data, we ensure clarity, set expectations, and enable seamless coordination across disciplines.”

With the entire structure delivered within just four months of final design approval, the project highlights how CD and DfMA drive efficiency, accuracy, and buildability in complex timber projects. The digital-first approach allowed for real-time adjustments, seamless collaboration between disciplines, and a construction process that was faster, more efficient, and more predictable.

The Future of Computational Design and DfMA in Timber Construction

At Theca Timber, we're at the forefront of using computational design (CD) and Design for Manufacture and Assembly (DfMA) to create innovative engineered timber structures. As timber construction and off-site prefabrication become more common in Australia, these digital methods will become even more crucial.

By applying CD and DfMA, architects and engineers can optimise structures for better performance, buildability, and sustainability, pushing the limits of what's possible. Automation in production will also streamline off-site fabrication, cutting costs and speeding up construction timelines.

We’re excited to expand the use of CD and DfMA across more timber projects, improving coordination, reducing on-site time, and maximising timber fibre efficiency. Federico sums up:

“The synergy between computational design and DfMA will play a key role in shaping the future of the built environment, enabling us to create structures that are not only more sustainable but also more responsive to the needs of both people and the planet.”

About Theca Timber and ENCODE – Design and Technology

Theca Timber and ENCODE – Design and Technology bring together expertise in engineered timber solutions and cutting-edge computational design to deliver innovative, sustainable, and efficient building projects. Theca Timber is a leader in providing high-quality, precision-engineered timber products, with a focus on mass timber and DfMA principles. ENCODE – Design and Technology, specialists in computational design, enable fast, iterative design and optimisation, ensuring that every project maximises performance and sustainability. Together, we seamlessly integrate design, engineering, and manufacturing to accelerate construction timelines, reduce waste, and create adaptable, high-performance timber structures. By leveraging the strengths of both companies, Theca Timber and ENCODE are helping to shape the future of timber construction, making advanced digital techniques more accessible and sustainable for projects of all scales.

Want to learn more about how we can transform your timber construction project? Get in touch to discover the power of computational design and DfMA.

Contact:
timothy@theca.com.au (NSW&ACT)
adam@theca.com.au (All other enquiries)