Robots, purpose, and a forest
Hooke Park’s 2024 The Tree and The Truss project is an outstanding example of Design & Build’s potential, more a philosophy than merely a methodology, says one of the project’s key architects, Manuel Artero Chávez Cornejo.
Architecture is at an inflection point. With the built environment responsible for over 40% of global carbon emissions, architects play a significant role in contributing to climate change. Additionally, building regulations are becoming increasingly condescending, encouraging hyper-standardisation, and prioritising risk reduction over design innovation. In this reality, architects face the challenges of sustainability, innovation, and cultural relevance. A Design & Build methodology presents a promising path into the re-valuation of the profession.
This piece explores how integrating Design & Build practices, embracing hyper-local materials, and leveraging digital tools can and are transforming architecture. Drawing inspiration from my experience as a M.Arch student at a place like Hooke Park (1), the Architectural Association’s Dorset woodland campus, it demonstrates that sustainability and innovation can be mutually reinforcing rather than opposing forces.
While technologies like 3D scanning, CNC milling and robotics are not new to the field, the real-world scalability of these new technologies is still at the exploratory stage. This is especially the case where building regulations, budgets, and material availability introduce constraints to projects. This issue unfolds into a broader discussion about the wider societal impact of adopting Design & Build methodologies as a particularly resilient and sustainable strategy and approach.
(1) Hooke Park is the Architectural Association’s 150-hectare woodland campus in Dorset, England, dedicated to design, construction, and landscape education, with a focus on climate change challenges. With a 30-year legacy of experimental timber construction, it features iconic round-wood buildings from its earlier phase. Since the AA took ownership in 2002, students have been actively involved in developing new facilities like workshops and Wakeford Hall. Hooke Park supports year-round activities, including AA courses, graduate programmes, visiting schools, and public events that connect it with the wider West Dorset cultural community.
The Essence of Design and Build
Design & Build is more than a methodology; it’s a philosophy that reconnects architects with the act of making. By integrating design and construction phases, architects can reduce waste, lower costs, and create buildings that respond directly to their environment. This approach also fosters a return to craftsmanship, where materials and context guide the design process. It also challenges the reliance on standardised, industrial solutions, offering bespoke alternatives that are both innovative and sustainable.
This holistic integration of design with construction brings back together the historical division between architects and builders. Mario Carpo’s research (2) illustrates this separation, which emerged due to societal fragmentation and representation limitations, leading to the separation of design and construction processes. This disconnect was further exacerbated by the Industrial Revolution and the advent of mass production. After a long period of increasing divergence, reaching a peak of separation, technology is now helping architects regain control over their projects, allowing them to design both architectural proposals together with construction processes.
Design & Build as a methodology implies the use and advantage of both worlds, a world of tradition and craftsmanship’s generational knowledge and newer technologies applied to each project. It’s not a set recipe; it’s flexible to adapt and deliver efficient solutions to each scenario as long as it is aligned with three fundamental principles:
1. Material Engagement: Prioritising locally sourced, non-industrialised materials encourages designers to embrace the materials natural irregularities and adapt their creations accordingly. This practice is evident at Hooke Park’s Design & Make Master Programme (3), where wood’s organic shapes (and forms) are digitally scanned and before being incorporated into projects.
2. Research Practice: Experimentation through full-scale prototyping refines both design and fabrication. Testing material limits and integrating multiple wood species exemplifies this iterative process, creating synergies between structural requirements and aesthetics.
3. Collective Model: Inclusive decision-making and shared knowledge networks help empower all involved stakeholders. By embracing traditional knowledge and modern tools, projects gain depth and adaptability.
These three principles combine to create what I like to imagine as a “spiral” methodology where each stage informs and refines the next, fostering innovation and resource efficiency. An open methodology like this allows and encourages the use of local materials.
(2) Carpo, Mario. 2011. The Alphabet and the Algorithm. Writing Architecture. Cambridge, Mass: MIT Press.
(3) Design & Make at Hooke Park is an advanced fabrica/on and experimental architecture programme based at the AA’s Hooke Park campus. It focuses on exploring architectural design through physical production, combining craO knowledge, innovative technologies, and natural materials. Supported by a team of experts, students develop design methodologies through full-scale projects driven by the principle of design-through-making. By integrating tools like 3D scanning, generative modelling, and robotic fabrication, the programme reconnects designer, maker, and artefact through dynamic feedback between material properties and form
Hooke Park’s lessons on hyper-local material
Hooke Park exemplifies the potential of hyper-local materials and woodland-embedded architecture. By sourcing timber directly from the surrounding 150-hectare working forest, its projects minimise transportation emissions while embracing the natural properties of the materials. Building on this foundation, the Design & Build methodology integrates advanced digital tools to optimise material use and scalability. For example, robotics and 3D scanning enhance precision while maintaining a hyper-local, sustainable construction ethos.
Hooke Park’s postgraduate programme ‘Design & Make’s ethos is reflected in its integration with the surrounding woodland ecosystem. Roundwood timber, a byproduct of local forestry, is transformed into structural elements through minimal processing, reducing transportation emissions and exploiting the material’s natural qualities. The educational and research platform reinforces this methodology by combining making and designing as inseparable activities, encouraging a new generation of architects to value craftsmanship alongside digital innovation.
Locally sourced materials, such as roundwood and clay, are key to reducing the carbon footprint of construction. Unlike industrialised materials, they require minimal processing and are inherently renewable. Digital tools enable architects to work with irregular forms, integrating these materials into designs that are both functional and expressive. This approach not only minimises waste but also respects the ecological cycle of the project’s environment.
‘The Tree and The Truss, the project I was part of during my MArch years at Hooke Park, is a prime example of this methodological approach, showcasing the use of non-standard, usually discarded and hyper-local resources. Scaling projects like ‘The Tree and The Truss’ presents opportunities for broader adoption of resilient, sustainable architecture. However, we must be aware of the challenges and limitations of trying to replicate a project like ‘The Tree and The Truss’. The Design & Build philosophy can be applied at any scale and in any scenario if we are conscious of the available materials and the combined skills of those involved in theproject. This requires an understanding of the balance between knowledge of digital tools and the local capacity, encompassing both theoretical knowledge and the practical skills necessary for making/building.
Digital Technology and Sustainability Considerations
Digital fabrication technologies, such as robotic milling and 3D scanning, are revolutionising construction by enabling bespoke designs. However, their environmental impact warrants careful consideration. While robotics can reduce material waste and enhance precision, the lifecycle emissions from manufacturing and operating these machines must be also taken into account. It is evident that computers and machines are tools needed in architectural design and construction. The key important aspect of the responsible use of technology is that beyond simply trying to balance its footprint by using renewable energies or adopting the repair-not-replace philosophy for these machines, we should focus on finding the right balance.
The environmental benefits of the Design & Build methodology are clear: reduced transportation emissions, lower material waste, and alignment with circular economy principles. But a true balance is only achieved by understanding about building and manufacturing processes, so we can tailor our design decisions into a more efficient outcome. By applying the essence of Design & Build – particularly identifying when it is more efficient to use digital tools, rather than simply replacing manual processes with machines – into their digital design and fabrication, architects can reduce the trade-offs of using machines. The goal should be to create a healthy synergy between the craftsmanship of working with non-standard materials and the capabilities of modern technologies, tailored to each specific scenario. This combination of hands-on techniques and digital fabrication lies at the heart of Hooke Park’s philosophy. ‘The Tree and The Truss’ project stands out as a particularly compelling realisation of this approach, showcasing a truly innovative and efficient outcome
An important factor to keep in mind is that the Design & Build methodology excels in contexts where conventional methods fail to be efficient. By adapting to site-specific conditions, it offers bespoke solutions that can make good use of the local materials available.
Roundwood Timber and Non-standard Techniques
Roundwood timber engineering represents a departure from industrialised building wood planks, embracing variability and reducing reliance on a standardised production. ‘The Tree and The Truss’ project demonstrates the potential of non-standard approaches to create structural solutions and bespoke architectural spaces that embrace wood as a natural material.
Model of the Truss system 
The natural forms integrated in architectural spaces embody invaluable qualities such as spanning strength, organic curves, and the essence of biophilic design. When these features are incorporated into a building, they help create a profound connection with the space, as if one is transported into a forest. Using a tree’s roundwood forks’ vertical strength in the columns, creates a powerful example of the immense remarkable potential of nature-inspired design.
This is in contrasts to mass production methods, which prioritise uniformity at the expense of local adaptation, innovation and materials specific qualities. By working with natural variability, a Design & Build approach methodology leverages non-standard materials to craft contextually responsive designs, aligning with sustainable practices and celebrating the inherent beauty of natural resources.
‘The Tree and the Truss’ is the third phase of a larger architectural project known as Wakeford Hall at HP. The project is a harmonious blend of traditional woodworking techniques and modern digital fabrication. As a multi-phase construction project, Wakeford Hall has evolved during its multi-year development, showcasing the institution’s commitment to sustainable and innovative design. From its inception, the project has focused on creating a landmark space that emphasises collaboration, education, and a deep connection with nature.
Initiated in 2017, the project has involved the design and construction of an initial glue-laminated mega structure, named ‘The Skeleton’, to test its capacity for withstanding high tension forces. In 2018, Phase 2 ‘The Envelope’ consisted in the addition of a structural envelope around the glue-laminated structure, marking the evolution of the design into a functional space. In the current Phase 3 (The Tree and The Truss), the building extension is composed of a 5-axis structural system covering approximately 320 square metres. Each phase reflects an ongoing dialogue between design, material, and context.
Central to the project is the use of only locally sourced timber, with an emphasis on incorporating typically discarded tree elements such as stumps, forks, and small branches. This approach not only minimises waste but also significantly reduces the project’s carbon footprint. Advanced technologies, including photogrammetry, CNC milling, and robotic machining, have been employed to achieve precision in shaping the main components such as stump bases, fork columns, glulam connections and truss chords. These technologies allow the design to pay tribute to the organic qualities of the wood while meeting its structural requirements.
The key structural components also underscore the project’s innovative and resourceful design approach. Cedar stumps, selected for their resilience and ground durability, were used as bases, through photogrammetry and precise robotic carving these components feature a
scarf joint connection with the columns, inspired by traditional Japanese joinery, with the scarf joints providing both structural stability and a natural aesthetic. The beech fork columns, carefully handpicked by our team of students from Hooke Park’s 150-hectare forest, were digitally scanned and machined to achieve the spatial considerations needs of the architectural design. The joints were pre-cut with the help of the 6-axis robot arm, and as a clear example of true balance, finished with a hand-router that proved to be five times faster and with the same level of precision.
Scarfing jointed cedar stumps and beech fork columns 
The next components are the glulam connectors that act as shape and angles negotiators, allowing a seamless integration with the fork columns and the truss system. These glulam connectors were crafted from 5 different layers of Norway spruce planks, aligned with the specific structural forces and geometries required by the design. The final glulam piece was then milled in the CNC machine and finished with hand tools. Norway spruce is widely available at Hooke forest and the planks were milled from logs that had been seasoned in situ for a year. We dry-kiln them roughly in our converted container kiln during the months leading up to the final processing and dimensioning of the specific planks.
Principal truss components – photo Rafael Ferres
Finally, the truss system brought together custom tension and compression web members, each one focused on showcasing the type of force they were subjected to. The compression web was fully produced by the robot arm in contrast with the tension web members, realised fully through manual processes. The whole truss system includes custom hardwood inserts (made of local ash) positioned at the structures most critical connection points, strengthening the resistance of the softwood trusses, against a 5-tonne tension force. The chords once again utilise Norway spruce planks processed by us, while the web members put in value the branches from the felled beech tress used for the fork columns. These elements were designed not only to handle significant structural loads but also to showcase the natural beauty of the materials.
Extensive prototyping and teseng were integral to refining each component. Teseng is a fundamental aspect of Design & Build as it’s the only way to prove the real resistance and behaviour of these structural elements to engineers and building regulators. A further aspect of the project was the pursuit of achieving a wood only structure. The use of scarf joints, dowels and wedges not only aesthetically appealing but also helps to maintain the true essence of building solely using local resources.
At its core, ‘The Tree and The Truss’ project for the Wakeford Hall Building, represents a thoughtful engagement with sustainability and material resourcefulness. By maximising the use of non-industrial materials and embracing advanced technology, the design process minimises waste while enhancing spatial quality. This landmark structure embodies the symbiotic relationship between architecture and nature, serving as both a functional space and a living repository of knowledge for the Hooke Park community.
Ethical and Social Dimension of Design and Build
From Adolf Loos (4) back in the 80s to Peggy Deamer (5) in 2020, architects keep talking about spatial justice as the one thing that we can offer back to society. Providing solutions that ease access to high quality architecture should be a fundamental part of our responsibility. Spatial justice is the way to ensure that the built environment is designed in a way that benefits all segments of society, especially marginalised communities.
An open methodology, such as Design & Build, allows multiple people and communities to participate in different parts of the process and particularly facilitates, and encourages, the integration of traditional building methods. This approach not only preserves heritage through giving value to craftmanship but also encourages innovation.
If we open the process from design to construction, we are promoting a more collaborative workflow that empowers diverse voices like stakeholders, community members and local authorities.
(4) Loos, Adolf. 2019. Ornament and Crime: Thoughts on Design and Materials. Translated by Shaun Whiteside. [London] UK: Penguin Books.
(5) Deamer, Peggy. 2020. Architecture and Labor. New York London: Routledge, Taylor & Francis Group
To keep in mind…
Design & Build represents a transformative shift in architecture. By integrating local materials, digital innovation, and collaborative processes, architects can create sustainable and resilient buildings that respond to the challenges of the 21st century. As the climate crisis intensifies, this methodology offers architecture a structure that is not only functional but also deeply connected to its environment and communities. The tools and knowledge to implement this approach are available, but the question remains whether we will use them.
The methodology, as exemplified by Hooke Park’s Design & Make projects, presents a viable path toward sustainable and resilient architecture. This approach challenges the current construction paradigms by embracing local materials, iterative research, and collaborative practices. Scaling its adoption requires overcoming technological and logistical obstacles while maintaining ethical and environmental commitments.
As architects are gradually able to integrate design with making, this methodology has the potential to redefine architecture’s role in shaping a more sustainable future. This transformative approach generates synergy with nature by working with naturally shaped materials and helping reduce carbon footprints. The choice is ours: to continue with conventional practices or embrace a transformative approach that harmonises innovation with nature, ensuring a legacy of resilience and sustainability for future generations.
The Project in Motion
It’s been over a year since I moved out of Hooke Park in March 2024, and The Tree and The Truss is still progressing. I have been fortunate to return more than a couple of times to work on the final finishes and pre-assembly of components for the 5-axis structure we designed and built back in 2022–23.
The original team of students involved in the project included the 2022–2024 Design & Make MArch cohort: Miguel Arturo Chávez Cornejo, Rafael Ferrés Echavarren, Sai Snigdha Pinisetti, and Yiling Zhou, as well as the 2022–2023 Design & Make MSc cohort: Yungang Chen, James Kristian Dent, Maisie Hoile, Guixin Lin, JoaquÍn Mosquera Iragorri, Yiting Sun, and Yifan Wang.
In fact, four of us are still involved in the project in various capacities. Through the summer of 2025 we have had a final Build Week at Hooke Park with volunteers from the Architectural Association main campus and the current Design & Make students and completed the last details necessary for a smooth installation process.
Miguel Chavez-Cornejo is a Peruvian Architect based in UK, who is deeply interested in innovative design solutions that blend technology with traditional craftsmanship. He received a Master’s degree in architecture with distinction from the Architectural Association, focused on design and makemethodology, highlighting responsible architecture and is passionate about locally sourced materials, aiming to empathize the societal impact of purpose-driven design.
Miguel presented the ‘The Tree and The Truss’ project at Fourth Door’s 2024 Pioneering the Potential Micro-conference.
Further
Material Sourcing
Some Numbers
This preliminary analysis uses precise volume data from a 3D model, which incorporates all project elements, including 3D-scanned round wood and as-built final components. A more detailed calculation is pending, but I believe the significant benefits and positive impact of using available local wood as a construction material are evident.
Important note for A5:
During the early stages, it took six people less than 15 hours to install and later dismantle two axes on site. The installation process was part of the decision-making during testing and prototyping and a key aspect of the design process that helps reduce the impact of the construction and installation phase.
Further calculations:
Applying these values to the total weight of The Tree and The Truss, we find that the most widespread industrial systems (which are good practices) have total embodied carbon values that seem only slightly higher for the same structural weight. However, this calculation does not yet account for the additional weight and volume that a structure using CLT or Glulam would likely require to cover the same area, nor does it consider the transportation emissions associated with these industrially manufactured materials.
CLT 761.86 kgCO₂e 119%
Glulam 853.28 kgCO₂e 133%
