Manufacturing | Formwork - Automating Complex Deck Formwork with Rhino.Inside.Revit

Hybrid Geometry Pipeline

We developed a unique architecture that extracts geometry from Revit but processes it entirely in RhinoCommon.

• The Bridge: Upon startup, the tool extracts Revit elements (Walls, Slabs, Beams) and converts them into our internal geometry types.
• Headless Solving: Once converted, the application disconnects from the Revit API. It uses Rhino's advanced Brep (Boundary Representation) kernel to merge, split, and heal the geometry - tasks that would be impossible or incredibly slow in native Revit.
• Metadata Preservation: To maintain the link between the solver and the original BIM data, we invented an IPointReference system. This injects metadata markers into the Rhino geometry, allowing the solver to query properties (like Wall Type or Element ID) without ever calling the Revit API.

Algorithmic Solving (Guillotine Cuts)

To tackle the layout optimization, we implemented a Guillotine Cut Algorithm.

• Wayfinding: The solver treats the ceiling as a navigation grid (20mm × 20mm), analyzing edge and corner conditions to "map" the space.
• Bin Partitioning: It strategically slices the irregular ceiling profile into rectangular "bins" that can be efficiently packed with standard panels.
• Structural Logic: The algorithm automatically inserts beam soffits and structural prop heads beneath each bin, ensuring the layout isn't just geometrically efficient, but structurally sound.

Enterprise Features

• Inventory Management: The tool accepts Excel-based inventory lists, prioritizing the client's existing stock before "ordering" new components.
• Strategy Pattern: The rule engine uses the Strategy Pattern to swap logic at runtime—handling over 1,00 distinct rules for corner conditions, slab thickness, and beam intersections dynamically.
• Interactive UX: An embedded Rhino Viewport allows users to visualize the solved formwork in 3D before committing it to Revit, bridging the gap between algorithmic logic and user verification.

UX & State Persistence

To ensure the tool was production-ready, we wrapped the complex backend in a modern WPF interface styled with Material Design.

• Visual Feedback Loop: An embedded Rhino Viewport allows users to visualize the algorithmic solution in 3D before committing to Revit. This renders a live view of the architect’s shell model overlaid with deck-specific metadata, providing immediate visual correlation between the selected room in the UI and its physical spatial context.
• Smart State Management: We implemented a JSON-based caching system that tracks every element created by the solver. When a user re-runs a solution, the tool deserializes this state to "re-attach" to existing families, deleting only the stale elements before placing the new design. This ensures a clean file state and prevents duplicate geometry, even after the session is closed.