The environmental impact of the construction industry (CI) is no longer a matter of debate. On the other hand, society is in a constant race to build bigger and more audaciously. To mitigate these competing directions, CI is turning to geometry and computation to reduce new material consumption and to improve the structural properties of buildings. Aluminum, with its remarkable weight to stiffness ratio and its natural anticorrosive properties, is at the forefront of this endeavor. For structural applications, aluminum is mainly used in its extruded form, while the rolled (sheet) material is preferred for architectural finishings and non-structural applications due to its low stiffness. However, with the advent of computational design and ubiquitous 2d CNC cutting, sheet metal can be used for bespoke architectural applications that combine aesthetic, structural, and environmental innovations. This paper will present two research projects developed in an academic setting at University of Montreal’s School of Architecture that use low thickness aluminum sheets to build bespoke architectural structures. The first project highlights an innovative use of surface discretization and assembly tabs to induce stiffness in large-scale doubly curved architectural surfaces and thus produces complex, free-standing aluminum surfaces with no support structure. The second project introduces a new folded low-tech ultralight aluminum node (300–400 gr) that is used to produce complex reticular wooden structures with nonstandard angles using reclaimed 2 × 4 wooden studs. Both projects culminated in full-scale research demonstrators with architectural pavilions exhibited on the university campus in 2021 and 2022.