A generative BIM approach for DfMA integration into building facade design

The application of Design for Manufacturing and Assembly (DfMA) in facade design faces barriers due to fragmentation between design and manufacturing teams and limitations of traditional modelling. This paper develops an automated generative design workflow that integrates DfMA principles into facade cladding system design using Building Information Modelling (BIM) and visual programming tools. The methodology uses multi-objective optimization via genetic algorithms to minimize incomplete panels, reduce material waste, and enhance manufacturing efficiency while preserving design intent. A medical centre case study in Melbourne demonstrates the workflow’s application across wall sections with varying orientations and geometries. The generative approach identifies optimal 1.85 × 2.5 m panel configurations, achieving 38.17% waste reduction in vertical orientation versus 57.09% in horizontal, and outperforming manual panelisation by up to 18.92% in material efficiency. The workflow enables real-time collaboration between designers and fabricators through parametric feedback loops, allowing fabrication constraints to inform design decisions during concept development. Analysis of 48 design alternatives reveals that systematic algorithmic optimization improves panelisation efficiency and identifies universal optimization principles for facade systems. This research presents a working prototype that integrates DfMA into standard BIM workflows, offering a replicable framework for automated facade optimization with demonstrated gains in material efficiency and manufacturing coordination.