Spatial Monoliths: From NURBS Data to Hand-Cast Sculptures

The Spatial Monoliths series (2025) explores the intersection between digital precision and traditional craftsmanship through a workflow that translates NURBS-based geometry into physically cast objects. Developed as a personal investigation, the project bridges parametric design in Rhino with hands-on mold making and casting techniques, resulting in sculptural artifacts that embody both computational logic and material expression.

With approximate dimensions of 50 × 30 × 70 cm, each piece functions as a spatial transcription of abstract structures, where geometry, texture, and material behavior are tightly interconnected.

*Parametric texture generation in Grasshopper, distributing geometric components across the surface.*

DESIGN & DIGITAL WORKFLOW

The process begins with analog sketching, which is then translated into a NURBS environment in Rhino. This transition enables direct manipulation of surfaces using curves, allowing for precise control over continuity, structural behavior, and manufacturability.

Beyond formal development, Rhino plays a key role in validating geometry from both technical and fabrication perspectives. Surface quality is refined using the XNurbs plugin, ensuring clean and controlled transitions suitable for downstream processes.

*Surface unrolling and part extraction in Rhino, preparing geometries for fabrication.*

Grasshopper is used to generate surface textures by applying parametric patterns onto selected geometries. Through a system of blocks distributed across surfaces, the script introduces controlled variation and complexity while maintaining coherence with the overall form.

Additional Rhino tools, such as CreateUVCrv and ApplyCrv, are used to map these textures onto surfaces, while UnrollSrf enables the flattening of geometry for fabrication. Edge curves are extracted using DupFaceBorder and exported as DXF files for laser cutting.

*Optimized nesting layout of components to minimize material waste before cutting.*

FABRICATION STRATEGY & MOLD DEVELOPMENT

A central challenge of the project is translating digital geometry into a precise, constructible mold system. Individual surface components are arranged into cutting layouts optimized for material efficiency, minimizing waste during fabrication.

The molds are produced from transparent PMMA sheets cut using laser technology. This material choice is critical, as it allows full visual control during casting—enabling monitoring of resin flow, detection of air bubbles, and evaluation of wall thickness, particularly under backlit conditions.

COMPUTATIONAL DESIGN WITH GRASSHOPPER

The assembly process directly references the Rhino model, ensuring alignment between digital intent and physical construction. This includes verifying tilt angles, edge conditions, and spatial relationships between components.

Structural stability is achieved through the integration of support ribs, which prevent deformation during casting and maintain geometric accuracy. This tight feedback loop between digital model and physical assembly ensures a high level of precision and consistency.

*Laser cutting process of PMMA sheets, translating digital outlines into physical mold elements.*

CASTING PROCESS & MATERIAL TRANSFORMATION

The sculptures are cast using a specialized polyurethane resin designed for rotational casting. This process allows the material to distribute evenly along the mold surfaces, producing a homogeneous shell regardless of geometric complexity.

*Assembly of the transparent mold structure, aligning parts according to the digital model.*

Due to the vertical proportions and stress concentration in narrower areas, an internal metal reinforcement system is integrated to ensure structural integrity.

After curing, the pieces undergo post-production processes including grinding and surface finishing, resulting in a unified monochromatic appearance that emphasizes form and texture.

*Prototype testing and physical verification of geometry, proportions, and structural behavior.*

RESULTS & CONCEPTUAL FRAMEWORK

The resulting objects represent a convergence of computational design and material experimentation. Rather than functioning as purely formal artifacts, they can be understood as spatial recordings of dynamic systems.

*Final sculpture displayed in exhibition, emphasizing composition and spatial balance.*

Rado Hrcka’s broader practice explores the relationship between mass and sound, treating geometry and sonic structures as parallel expressions of the same investigation. Within this context, the Spatial Monoliths act as physical manifestations of abstract rhythms and frequencies, translating intangible phenomena into tangible form.

Currently exhibited in gallery environments, the sculptures complete a workflow that moves from digital modeling to autonomous physical objects, maintaining a strong fidelity between data, process, and material outcome.