The Stanley team embraced this challenge, first building a prototype to brainstorm the best way to construct this unique project. A two dimensional construction plan was extracted from a three dimensional CAD design so panels could be individually manufactured. The interior and exterior of the Kakano are each made up of 268 triangular panels, every one different and fitted together with a ‘tenth of a degree’ of accuracy.
A Computerised Numeric Cutter (CNC) was used to create each panel with the accuracy of half a millimetre.
The team came up with innovative solutions to the complex build and had to counteract the effects of gravity on the structure during the construction process, as the structure is only sound and capable of holding its weight once complete.The finished product is one of exceptional character, clever workmanship and creativity. With a TVNZ show ‘The Art of the Architects’ following its progress; Kakano will star on their new series planned for 2012.