system812: DfMA + Digital Twin by Andrew Klenke

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01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 01001100 01101111 01100111 01100001 01101110 //Logan Brammeier 01101111 00100 0100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 011 1101100 01000011 01101000 01100001 01110010 01101100 01100101 01111001 //Charley Devries 01101100 011011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01010010 01101111 01100010 01100010 01101001 01100101 //Robbie Edberg-Oostdik 01101100 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1101111 00100001 01101111 01010011 01101000 01100001 01110111 01101110 //Shawn Khokher 00100000 001000 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1001000 01100101 01000001 01101110 01100100 01110010 01100101 01110111 //Andrew Klenke 01101100 0110110 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01010110 01101001 01100011 01110100 01101111 01110010 //Victor Renteria 01101100 0110110 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01010010 01100101 01100010 01100101 01100011 01100011 01100001 //Rebecca Twombly 01100101 01101 1101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 001 0100000 01001000 01100101 01010100 01111001 01110011 01101111 01101110 //Tyson Washington01101100 01101 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 011 1101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 001 1001000 01100101 01101100 01010000 01100001 01101111 01101100 01100001 //Prof. Paola Sanguinetti 01101100 0 0100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 010 1100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 011 0100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 010 1100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 011 0100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 010 1100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 011 0100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 010 1100101 01101100 01101100 01101111 00100001 00100000 00100000 01001000 01100101 01101100 01101100 011 0100001 00100000 00100000 01001000 01100101 01101100 01101100 01101111 00100001 00100000 00100000 010 1100101 01101100 01101100 01101111 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//system812 //DfMA + Digital Twin

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//DfMA Residential //Construction //AndrewKlenke

During this studio, I focused on creating a set of design tools for common architectural softwares in order to make prefabricated construction for residential projects easier for designers and manufacturers. ••• Andrew Klenke University of Kansas Fall 2020 - Spring 2021

Research Design for Manufacturing and Assembly, also referred to as DfMA, is the design though process of making parts easier to assemble or install, by heavily studying and improving the installation process and simplifying the product. Examples of DfMA exists in many industries from computers and technology to automobiles and airplanes. Currently, while many industries push forward with new technology such as automation, the construction industry has been very far behind and lagging. There are many companies pioneering what DfMA and automation look like in the A/E/C industry, but as whole the industry likes to take the more traditional approach of building everything peice by piece. Currently there are only a handful of things that are delivered to the site prefabricated. This typically includes windows, doors, mechanical equipment, etc. But what if the structure, walls, and the ductwork all came pre-fabricated like a puzzle piece, just ready to go together. This would possibly leave only the foundation system left to do on site, besides part connections and assembly. That said if the industry could dive deeper into theses methodologies as a whole, construction would be more efficient in both time and cost.

Initial Research Existing prefabrication construction is currently split between two main styles. The first is Modular construciton, which is where whole segments of the building are manufactured off site, and then lifted into place, greatly reducing the amount of on-site time and expenses. The second is kit-of-parts style, where all the panels are brought to site and assembled there, which still leaves work to do on site.

Modular

Kit-of-Parts

RESEARCH

Kit-of-Parts Using the kit-of-parts system of prefabricated constuction allows for greater flexibility in design, transportation, and construction. For travel and delivery, the peices are limited by thier size, and not the size of the overall building. They can also be arranged in many different configurations while using the same catalog of parts. During my research I looked at companies like Katera and Cover. One of the downsides of these systems, as seen in the photos below, is they are very custom peices, so any modification or changes in the future would be limited to that system.

RESEARCH

Modular This prefabrication method is the best for spending the least amount of time on site. For sites such as those disrupted by weather, or even urban sites where construction is difficult with road blockages. This method would be the quickest on site. One of the limiting factors of this type of system, is that the modules are limited by thier size. Typically not wider than 14’-0” wide, and some are up to 13’-4” tall, and 50’0” long. However, site location and travel routes should be considered when choosing this method, and the size of the modules. This system doesn’t work well for big open spaces, and its stacking construction makes it perfect for repetitive building typologies like hotels and residential buildings.

RESEARCH

Proposal My proposal would be to factory create modular units that are assembled from an inventory of existing parts that are designed to work together. This would take advantage of the modular construction type and the kit-of-parts construction types. Not only would site installation be quick and easy because of the completed modules, but the building of the modules in the factory would be extreamly quick if there was an inventory of parts readily available as orders come in.

The module to the right is how the structural part of the module would look before leaving the factory. The interior work and panel boards are not shown for clarity. Since there are double rim joist at the cieling, and the floor of the unit stacking above, there may not be required dropped beams over windows, giving clear floor to ceiling views. Under higher loads, either the 2x Rim joists can be changed to an LVL or a dropped beam can be added.

Proposal Outline What? •

Creating a hybrid construction model using the best portions of the Module and Kit-ofParts method.

Why? • •

Reduce time spent on site: - Time and cost savings - Avoid weather delays Reduce time spend on manufacturing: - TIme and cost savings - Optimization and assembly

How? •

•

Use Kit-of-Parts for Module construction - Catalog and inventory of parts to be used and ready for any module combination Ship module to site for installation - Module limited to a max size and ready to be delivered and installed on site in a quick manner.

Phase 1 Schematic Design Wasp Script Using the WASP tool box plugin for Grasshopper, you could use an imput curve to bound the aggregation to. At 0 modules just the curve is visible. Each aggregation is random, and is unlikley to be the same each time around. Though they are visually very similar. As more modules are added, they begin to grow around the curve. The dark green to yellow color representing the recency of the modules placed in the aggregation from oldest/orgin to the most recent, respectivly. As the modules grow around the bounding curve, they begin to grow/branch out, making the growth wider. As more modules are added the script begins to lose a practicality to it, as the randomness of the module placements are unrealistic for an organized architectural program. At 1000 modules placed, it is clear the randomness of the module placement has no real-world application, as modules closest to the center guide lines have no source of natural lighting or escape route, and thus can’t be used as a habitable space for residential construction. This style could be applicable for commericial, though the column spacing would be too short and frequent.

0000 Modules

0119 Modules

0005 Modules

0232 Modules

0034 Modules

1000 Modules

PHASE 1

Schematic Design Module Script The first section of this script takes user selected input curves to define the center/hallway layout of building foot print. These can be drawn in any linear based shape, making any arrangement to meet the desired site plan which can be used to trace over. The second part of this script offsets the guide curves based on the hallway width as well as the max module length the user wants to design with. Based on this the script finds the faces of the perimeter that can support modules. The third part of the script divides up the possible module host curves and finds the module’s orgin point along the curve. Taking the origin point and the normal vector from the last modules are placed on every orgin point along the offset host curves. Based on the maximum height of the building and the max height of the modules, the number of floors is determined and the modules are then stacked above. With the main goal of this script to be a visualization and planning tool, there is a need to extract the data and send to a more developed software like Revit. Extracted are two points that make up the origin and the normal vector. These points are broken into thier cartesian values and exported to an Excel/CSV file as a vehicle to import into Revit/Dynamo.

Input Curves

Module Alignment

Offset Curves

Visualization

Divide Curves

Extract Origins

PHASE 1

Rhino to Revit Converter The first part of this script imports all of the module origin points as well as the end point of the normal vector to the origin. This is necessary to determine the location and orientation of each module to be placed. They can then be placed at any and every angle in the workspace. The second part of the script places a generic mass family the size of the appropriate mass at each origin place and rotates it to the correct normal direction. These masses can now be used as face hosts for the Kitof-Parts to be applied to it in further scripts.

Import Origins

Revit Module Placement

PHASE 1

Kit-of-Parts Catalog By having a catalog of commonly used parts, we can streamline the construciton process, and by understanding up front how the catalog works, allows for better design.

P4.4X.12.L1.R0

P4.4X.12.L1.R2

P4.4X.12.L2.R0

P4.4X.12.L2.R2

P4.4X.16.L1.R0

P4.4X.16.L1.R2

P4.4X.16.L2.R0

P4.4X.16.L2.R2

P6.4X.12.L1.R0

P6.4X.12.L1.R2

P6.4X.12.L2.R0

P6.4X.12.L2.R2

P6.4X.16.L1.R0

P6.4X.16.L1.R2

P6.4X.16.L2.R0

P6.4X.16.L2.R2

P4 . 4X . 12 . L2 . R2 A

A - Panel Stud Size P4 - 2x4 Studs P6 - 2x6 Studs

B - Panel Width 4X - 4’-0” Wide Panel by X’-X” Tall

C - Stud Spacing 12 - 12” OC Spacing 16 - 16” OC Spacing

D - Number of Left Studs L1 - (1) 2x Stud on Left L2 - (2) 2x Studs on Left

E - Number of Right Studs R0 - (0) 2x Studs on Right R1 - (1) 2x Stud on Right R2 - (2) 2x Studs on Right

PHASE 1

Wall Assembly Each of the (4) walls of the module being constructed can be built from the kit of parts. And the overlapping osb sheathing of each panel allows for secure connections to the upper and lower double rim joists, creating a solid structural system.

P4.4X.16.L1.R2

WINDOW

P4.4X.16.L2.R2

WINDOW

P4.4X.16.L2.R0

Phase 2 After my final review in the fall, I decided to change direction for the spring, based on some of the feedback I was given, especially regarding the space and availbility needed for storing a library of building pieces, versus being made to order.

Automated Structural Framing Taking a simple architectural model of built-in revit elements, such as roofs, walls, and floors, and then creating workflows that would automatically provide framing layouts and sizes. This would greatly benifit structural designers, and applies to prefabricated construction systems like SIP walls.

PHASE 2

Framing Modules and Digital Twin To start, I broke down a simple model into its seperate construction and element typologies, such as the roof, wall, and floors. By breaking them down individually, we can apply the approriate workflow and calculation methods for determining the framing.

Roof Module

Wall Module

Floor Module

PHASE 2

Revit Built-in Elements The code starts by pulling into Dynamo the built-in revit elements such as a wall. Elements such as doors and windows that are hosted to the walls would be pulled in too.

Extracting Structural Layer

Exporting Openings Each opening in the wall, is also extracted and can be exported to determine the needed structural header above the opening.

The wall elements are then sent through a python section of the script, where Revit API commands are called upon to extract the structural layer, its thickness, and its material. Using the by-parts method, we utilize Revit’s automatic layer joining at corners and joints.

Structural Analysis

If the openings are exported they can be taken into a structural analysis software where the size can be determined and imported back into the model. For projects using the IRC codes, prescriptive header sizes can be applied through a data base of the code.

Importing Structural Results The result of the structural analysis would be brought back into the model. Based on the calculations, a header size would be provided, as well as the jack and king studs supporting the header.

Wall Framing Lastly, the rest of the wall panel would be framed in with infill lumber at typical framing spaces, based on the walls level and the number of floors or roofs supported from above.

PHASE 2

Construction Render

PHASE 2

Construction Render

PHASE 2

Construction Render

PHASE 2

Construction Render

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