Project details

Automating everything

The Sphere in Las Vegas is a project recognized worldwide. Designed by Populous Architects and opened in 2023, it stands as a marvel of modern architecture.

We worked on this project for almost two years, automatically generating and preparing for production every single detail of the inner structure. We developed custom Rhino Plug-ins (C#) and Grasshopper definitions to automate the creation of the full Digital Twin for the entire interior LED screen structure with 0.001mm precision, preparing it for production fully automatically.

Starting with very simple input geometry, we created the primary, secondary, and tertiary structures (plus the LED screens) "at the click of a button." This included every single metal plate and screw, down to the screw threads. We generated precise 3D geometry and exported CNC files for more than 30,000 unique aluminum profiles fully automatically. Each of these 30,000 profiles required more than 150 unique CNC operations (drill, thread, pocket, mill, etc.). In the end, every single profile was exported as both a 3D file and a CNC file (G-code) that went directly into the machines. All the part lists (screws, plates) were generated automatically, as well as all the necessary workshop drawings (2D).

If you are interested in more information, give us a call any time, and we can chat.