What design considerations are important when customizing a metal cladding wall for curved or irregular façades?

Curved or irregular façades impose additional design, fabrication and installation challenges that must be anticipated early. First, consider material formability: some metals and thicknesses can be cold-bent to radii, while others require segmented panels or bespoke cold-roll forming to achieve curvature. Panel joint design must accommodate compound geometry; narrow joints or stepped panels may be needed to maintain visual continuity while allowing manufacture. Tolerances tighten on curved surfaces — substrate geometry, secondary framing, and panel nesting should be modeled in 3D (BIM) to detect clashes and ensure precise alignment. Custom brackets and adjustable support rails allow panels to adapt to complex geometries and compensate for site tolerances. Fabrication complexity increases with curvature and irregular shapes: CNC cutting, custom press braking or even hot forming might be used, and lead times should account for bespoke tooling. Thermal movement behavior differs on curved surfaces, so clip design and expansion joints must be engineered to prevent buckling or fatigue. Mock-ups, either full-scale in critical zones or sample panels, validate appearance, joint behavior and waterproofing before mass production. Logistics of transporting irregular or curved panels require careful packaging and protected lifting frames. Close collaboration between architect, façade engineer and fabricator ensures the aesthetic intent is met while maintaining structural integrity and installability for complex cladding geometries.