A version of this blog first appeared as “Why does a design firm need a fabrication shop?” in Design Quarterly, Issue 29.
For centuries, architects were more than designers. They were master builders, guiding projects from concept through construction and overseeing every stage of the process. As buildings became more complex, that work evolved into specialized disciplines. That change separated design, engineering, and construction into distinct professions.
Today, digital technology is reshaping that relationship. The 3D model has become the shared source of truth for project teams, allowing architects, engineers, and builders to collaborate in new ways. At the same time, many design firms are rediscovering the value of hands-on making. Physical models, prototypes, and mock-ups can reveal design challenges and test ideas. They can help teams to better communicate concepts.
Few people understand the intersection of digital design and digital fabrication better than Matt Vaclavik. He leads our fabrication studio, also known as the Fab Lab. Working with a close-knit team of skilled makers, Matt helps transform digital concepts into physical prototypes, installations, and models. The team uses a variety of tools, including computer numerical control (CNC) routers and laser cutters.
We spoke with Matt about his career path, the role fabrication plays in today’s design process, and why some of the most memorable projects come with a tight deadline.
" }Physical models help design teams explore ideas, identify challenges, and communicate design intent. The fabrication studio in Houston, Texas, helps create them.
How did you come to lead the fabrication studio?
Matt: About 15 years ago, I moved to Houston for a satellite graduate program through Texas Tech University. There, I met my professor and now colleague John Clegg. After graduate school, I spent nine years as a designer and project manager at a classical architecture firm, working on projects ranging from high-end residential to institutional design.
During that time, I pursued my interests in building, making, woodworking, and metalworking outside the firm. I would run into John occasionally, and he eventually invited me to lunch to discuss an opportunity. John and Arturo Chavez had a vision for a centralized fabrication space that could serve teams across the company, and they asked whether I wanted to lead it.
They believed making could be more than a way to represent ideas. It could become an integral part of the design process. That vision resonated deeply with me, although it was a leap of faith for all of us.
After studying fabrication spaces at other firms, we identified what we needed and launched the studio in Houston’s East End Maker Hub. Today, we have a 5,000-square-foot studio and access to a public makerspace within the 300,000-square-foot facility.
What is the fabrication studio, and how does it support project teams?
Matt: The fabrication studio is a firmwide resource serving project teams across North America. We bring together design, engineering, and making. We can help teams explore, test, and communicate ideas throughout the design process. Our work ranges from quick study models and design iterations to full-scale mock-ups, prototypes, and custom installations.
We can support projects of many scales and levels of complexity.
" }View of Athena, our five-axis CNC router.
More importantly, we are not defined by a single tool or process. We combine traditional craftsmanship with advanced digital fabrication to help teams make informed design decisions, communicate intent more effectively, and improve the quality of their work.
Athena, our 5-by-10-foot, 5-axis CNC router, gives us significant capacity and speed when producing prototypes, mock-ups, and model bases for project pursuits. It has made a real difference in what we can deliver.
What value does an in-house digital fabrication studio bring to the design process?
Matt: Historically, our industry placed a strong emphasis on models, prototypes, and mock-ups. We are beginning to see renewed interest in those tools because they help designers reconnect with materials.
Physical models also communicate design intent in a way that is relatable to anyone, not just someone who can read a drawing set. Much of what we do as designers involves communicating the effectiveness of a design and demonstrating it to clients and industry partners. Fabrication gives us another way to do that.
I see my role as a translator between design and the tools and processes used to make things. Rather than leading the design effort, our studio serves as a partner in the process. Our capabilities can help teams explore ideas, support research and development, and identify potential risks. Those are areas where our team can provide meaningful value.
" }What projects best demonstrate the value of physical models, mock-ups, and prototypes?
Matt: We’ve produced everything from quick, high-density foam study models to finely crafted hardwood presentation models. It’s difficult to choose a favorite because many are created under tight deadlines for project pursuits.
The projects that stand out most are the ones where we work with the design team from the beginning. We collaborate with the team, ask questions, test ideas, and help shape the design through making.
One recent example is Oscar, a technology cabinet for our ZenDen sensory spaces. It fits a projector, mini-PC, touch controls, audio, and lighting into an enclosure measuring only about 18 by 20 inches. We worked closely with the designers to confirm that it could be built. But we also approached it as a product by carefully considering its materials, details, and assembly. The result was a fully functional prototype that looked and performed like a finished product.
Another example involved a series of panel mock-ups for an exterior façade, developed with our team in Austin, Texas. The designers were exploring a color-shifting effect across perforated metal fins. They wanted to know whether it would translate from the digital model into the physical world.
First, we built a large-scale study model with more than 300 individual fins. It confirmed that the visual effect matched the renderings. Then, we produced a full-scale mock-up so the team could evaluate perforation size, color, and constructability.
The testing demonstrated that the overall concept worked, but it also revealed opportunities to refine the perforation pattern before construction. The mock-up gave the designers greater confidence, generated valuable technical feedback, and helped build client support. We are now assisting with a second round of full-scale testing. This is exactly the kind of collaborative, iterative work we want to do more of.
" }Oscar is a technology cabinet designed for our ZenDen sensory spaces. The Fabrication team and the ZenDen team created a technology-packed “product” to support our sensory design research.
Does the studio’s work ever become part of the finished project?
Matt: It does. But we are selective about the projects we take on. Our capacity limits the scale of what we can fabricate, so we focus on opportunities where we know we can deliver a high-quality result. Most often, that means producing mock-ups and prototypes, particularly for larger projects. However, when the right opportunity matches our capabilities, we are excited to create something that becomes part of the finished space.
One example is a plywood slat wall in our Los Angeles office. We collaborated with the Los Angeles team and prefabricated the wall in-house. We also coordinated with the contractor to install the backing panels, and a group of colleagues from the office installed the slats.
When does the fabrication studio become involved in a project?
Matt: Project pursuits are a significant part of our work because physical models can be powerful differentiators during interviews. However, we partner with teams throughout every phase of design. What we deliver changes as the project evolves.
During early concept design, small-scale study models can help teams explore ideas and communicate design intent. As the project progresses, the scale, complexity, and purpose of our work evolve to match the team’s needs. That might include detailed presentation models, full-scale mock-ups, prototypes, or other fabrication support.
" }The fabrication studio creates custom models for pursuits, interviews, and design presentations.
What gives you the most satisfaction about this job? It seems like a great fit for a maker with an architecture background.
Matt: I love solving problems. Whether we are creating a model, a mock-up, or something in between, the process challenges us to find an effective solution that supports the team’s goals. I enjoy seeing that vision come to life in built form.
I also have a passion for craft. We emphasize quality and craftsmanship to create tools that help teams communicate more effectively.
Finally, I am inspired by our close-knit team. We all share a passion for making, and many of the people who collaborate with us share that enthusiasm. Working with creative people each week, solving problems together, and seeing ideas take shape keeps me energized and inspired.
" }