Below is a short summary and detailed review of this video written by FutureFactual:
I-Beams from Fonts: Testing Typefaces as Structural Beams with Finite Element Analysis
This video follows James Dingley of Atomic Frontier as he treats letters like structural members, asking which typeface I would make the best I-beam. He builds scaled, 12x12 cm HDP plastic beams on a 4-axis CNC router, tests them with an Instron, and supplements the results with finite element simulations. The study surveys fonts from Google, Windows, and MacOS, including Kalamo, Borhyme, Archiola, Noto Serif, and Zapfino, among many others. While a traditional I-beam remains a solid baseline, certain fonts approach or exceed its load capacity in specific tests, and even outperform it when optimising flange geometry. The project culminates in a practical conclusion: among common typefaces, the best performers arise from O-shaped and rotated-H forms; the broader message is about material efficiency via geometry rather than aesthetics.
Overview: A Typography-Engineering Question
In this engaging exploration, James Dingley asks a playful yet rigorous question: can fonts be used as structural elements in bridges? The project traces a journey from type design history to modern fabrication and testing, treating letters as potential I-beams and evaluating how their shapes resist bending, buckling, tension, and torsion.
"This was a ridiculous idea" - James Dingley
Historical Context: From Gutenberg to Roman Type
The narrative grounds typography in its engineering origins, from Gutenberg’s bulky black-letter blocks to Jensen’s readable Roman type. This history frames the central idea: the geometry of letters matters not just for legibility but for carrying loads when repurposed as structural members.
In the end, the video argues that the true purpose of fonts can extend beyond text into the realm of shape optimization for engineering.
Methods: From Font Selection to Physical Prototypes
A key innovation is fabricating scaled I-beams out of HDP plastic within a 12x12 cm footprint. Fonts are scaled to fit, with 1000 fonts screened and a carefully chosen subset advanced to physical testing. The setup includes a traditional I-beam baseline, a CNC router, and an Instron test rig to measure ultimate strength.
"1,000 fonts later" - James Dingley
Simulations: Bringing Physics to Pixels
To supplement physical tests, the engineer writes a bespoke finite element analysis (FEA) code, then cross-validates with Instron data. The simulations break complex shapes into thousands of points connected by springs to mimic material behavior, capturing bending, buckling, and torsion under various loads. After seven days of coding and two days of simulation, the model shows how closely it tracks real-world behavior and reveals which letter geometries concentrate or distribute stress differently.
"The simulations mostly match up" - James Dingley
Results: Which Typefaces Make the Best I-Beams
Across tests, traditional I-beams provide a strong baseline, but several fonts outperform in bending tests when their flange geometry is optimized. Kalamo and Arial Black–style shapes show notable performance, while Zapfino consistently underperforms due to its ornate geometry. Among stock fonts, Courier New stands out for its near-identical behavior to a standard I-beam, underscoring the power of simple, straight-line geometry. The standout result is Borhyme, a Google font that replaces fillets with wider loading flanges and beats the baseline in the right loading scenario.
"the only one to actually beat it was Borhyme" - James Dingley
Takeaways: Practical Implications and Final Thoughts
Beyond the specific fonts, the project highlights a broader point: the shape and placement of material govern performance more than the letters' aesthetics. In particular, O-shaped and rotated-H geometries emerge as robust options, with Noto Serif’s O and Archiola’s rotated H performing best across multiple loading scenarios. The video also notes that some fonts, while visually appealing, perform poorly under certain stresses, reminding readers that beauty does not guarantee structural efficiency. The creator invites readers to explore the accompanying code, data, and a peer-reviewed paper describing the methodology and results, encouraging experimentation and community engagement.
"the O from Noto-serif and the rotated H from Archiola end up performing the best" - James Dingley
