What are common engineering challenges when designing complex geometries with a unitized curtain wall?

Designing complex geometries with unitized curtain walls introduces engineering challenges including panel geometry optimization, joint complexity, tolerancing, and transportation constraints. Free-form or doubly-curved façades require custom frames, bespoke gaskets, and occasionally non-rectilinear IGUs, which increase fabrication complexity and cost. Ensuring dimensional stability and tight tolerances for mating surfaces becomes more difficult as curvature and varying module geometry increase. Anchors and brackets often need bespoke design to account for variable panel angles and load transfer paths; misaligned anchors can cause panel distortion or stress concentrations in glazing. Transportation and handling constraints limit panel sizes and curvature radii, forcing design trade-offs between larger assembled units and field-assembled modules. Thermal and structural modelling of irregular geometries is more complex: localized wind suction, self-weight distribution, and differential deflection patterns need refined analysis. Interface detailing to accommodate movement while maintaining watertight seals requires innovative gasket and glazing bead solutions. Manufacturing capacity—special tooling, CNC programs, and skilled labour—must be evaluated early. Mock-ups and prototype fabrication are highly recommended to validate complex interfaces, and iterative collaboration between architects, engineers, and fabricators is critical to resolving constructability issues while preserving design intent.