AA_Environmental and Technical Studies_Final Thesis_01

between

the valley and the mountain

zineb sentissi

from a line to the third dimension

Technical studies 2018-02019 aa school of architecture Diploma 17

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TABLE OF CONTENT

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0.0 introduction 0.1 Project overview - Design brief 0.2 Technical Studies Brief - from 2d to 3d - The Crease

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Case study - One Fold - Patkau Architects

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1.0 design overview 1.1 Programatic Research

Free University Berlin - Alexis Josic, Georgis Candilis, Shadrach Woods Rolex learning Center- Sanaa

Case study: Hollow Column- Thracian Necropolis- Pomorie Case study : Sendai Mediatheque- Toyo Ito

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1.2 Tectonic Overview- The Inhabitable Column

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1.3 Tectonic components: Folded Column

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2.0 material study 2.1 Metals 2.2 Metal Forming

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Fabrication process : Panel Beating Fabrication process : Superforming Case study: Porshe Pavillon

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Manufactury visit : Morgan Motors Compagny Manufactury visit : James capper studio - metal sculptures Manufactury visit : Angler factory - Tube and section bending, metal braking

Fabrication process : CNC machining Test : Cnc cutting and scoring settings

Case study: Industrial Origami Test : Folding the pattern Test : Patterning and flexibility

Case study : Z folding mechanism Case study : Sogame- Ori

2.3Manufacturies visits

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3.0 fabrication part i - cut, score, pattern 3.1 The cut and the score

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3.2 The pattern

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3.3 Hinging the fold

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4.0 fabrication part ii - fold

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Fabrication process : Press Braking

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Case study : Robofold Test : Folding through robotic pulling

Test - One continuous curved crease Test - One continuous crease composed of a straihgt crease and a curved curved Test - Four creases composed of two valley lines and two mountains Test - Straight and curved creases Test - Two curved creases valley and mountain Test - Six folds composed of valleys and mountains

Column type I Folding Column type II Folding

4.1 Robotic folding

82 84 86

4.2 Manual Folding - Topography

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102 104 106 108 110 112

4.3 Manual Folding - Column

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5.0 fabrication part iii - cast 5.1 Folded Metal formwork

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Test - Planar cast Fabrication process : Cast on cast Test - Shotcrete Formwork Fabrication process : Tube and section bending Test - Concrete slip cast

140 146 148 150 160

5.2 Reinforcement strategy- hot wire foam cutting

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Fabrication process : CNC hot wire eps foam cutting

Fabrication process : Robotic hot wire eps foam cutting Test - Double curved Foam surface hot wire cutting

Test - Hot wire Foam Cutting

Test - Foam Formwork Test - Column casting in foam

Test - Foam reinforced metal Formwork

6.0 fabrication part iv - breaking down the fold 6.1 External flanges

Test - External flanges

Test - Internal flanges

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173 174 178

183 188

194 196 198

6.2 Internal flanges

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7.0 construction sequence

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8.0 accoustics

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9.0 structural simulation 8.1 Removing sides

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Test - Sound absortion and texture

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Simulation - 4 sides column Simulation - 3 sides column Simulation - 2 sides column Simulation - 2 sides column Simulation - 1 side column

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8.2 Creating an opening

10.0 conclusion

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0.0 introduction 0.1 Project brief 0.2 Technical Studies Brief- from 2d to 3d the crease Case study : One Fold- Patkau architects

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0.1 Project overview - Design brief

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Since 1600 the role of the architect separated from the master builder. These last 50 years witnessed the growth in complexity of the building environment we evolve in. In terms of Architecture, robots are modifying the way we build.

Researchers from ETH Zurich build “the first house in the world to be designed, planned and built using predominantly digital processes.” A black box. Technologies that are growing faster than their mastering leading to more specializing and compartmentalizing, embedding in our minds of the idea of a conflictual relationship between the human and the technology. The terminator myth.

Simondon underlines that, “we do not live in an over technician civilisation it is simply a maltechnician one”. In Southern China, the broad group development company built a 57-storey tower in a record 19 days. The implementation of technologies in architecture is not in adequacy with the contemporary stage of these technologies. Such a use of technology participates not only in the loss of agency of the architect but as well in the carrying out of standardisation of the built environment, participating in the settlement of cultural hysteresis. In each epoch manufacturers present objects having the same allure and external characteristics of the previous generation, what may cause a cultural delay. Even if the automotive field implements new technologies faster, most of the automobiles suffer from the constancy of their exterior. Frank Lllyod Wright “insisted that the industrialization of building need to not result in the standardization of form, all buildings should be machine made, but not two homes need be alike.

Imagination is the ability of the mind to be creative or resourceful. A valley and a mountain. A fold. The line becomes a crease, the creases populate a surface and then fold into space uncovering volume. Folding stimulates creativity, generates space, and complex assemblies. Throughout the bringing forth, the metal sheet carries the marks of the origination process of the project. Aiming to regain more freedom, folding is a testing ground which is not reduced to a formal architectural process but a strategy layering design, experimentation and fabrication.

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0.2 Technical Studies Brief - from 2d to 3d - The Crease

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The project is an attempt to rethink the original role of the architect and the design make relationship. The corporeality of the project being tied to the correlation between architectural design and building process. Especially in a context of virtualization of reality. Thus, challenging both the loss of agency of the architect and the carrying out of standardisation that nurtures a cultural hysteresis and delay.

Folding has merged various field from art to science leading to various technological innovations. Folding technics is a sustainable, and energy efficient production process. The folding can happen at different scales, among the challenges of the project is the shift to an architectural one coupled with the minimizing of the construction effort. This necessitates the merging of Human abilities and Teknik.

The hand brain eye coordination form a feedback loop. The research aims to mapping the and inventory of these transformations as a set of instructions that include location, operation, time, force. Can these set of instructions be translated into a machine?

Folding is thus not reduced to a formal architectural process but as a strategy layering design, experimentation and fabrication. It becomes a tool to envision, visualize and materialize. A reappraisal of every step of architecture from design to fabrication. The fold bridges between imagination and materialization.

The folding generates a new language and space through sequences of these transformation. Parent and Virilio’s oblique function, built up around the third spatial possibility for architecture. Sheet transformation triggers our thinking about process, tectonic, typology and space experience. Rotating, pushing, pulling, twisting, flipping, compressing, scaling, combining… Shifting process, form, structure or function. The Pli does set material in motion, holding in itself the Gestell of a continuous state of evolution.

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Trials to transpose the devellop a custum made machine to replicate the folding patterns discovered before but relying on a low tech tools. Using a custum made frame to fold an aluminium sheet from one point into 3 dimetional shape. Angles of freedom of the machine axis are very limited so is the fact that the structure emerges from only one fold which limits the design options

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Case study - One Fold - Patkau Architects

Case study object

Custum made metal folding machine What I have learned

The conventional punch-and-die press brake—which is used to fold sheet steel—becomes the subject of adaptation, and through an iterative process evolves into a unique device.

Structures with a high strength-to-weight ratios.

Minimal ecological footprint.

Patkau architects 2015 Vancouver- Canada

One Fold is an experimental project exploring the architectural possibilities of folding a single sheet of steel one time. The project takes its inspiration from a challenge put to origami artist Paul Jackson; make an origami sculpture with only one fold. One Fold takes on that challenge at the scale of inhabitable space.

To make that shift in scale demands a shift in material, from paper to steel, and that shift in material in turn demands a new technique. The conventional punch-and-die press brake—which is used to fold sheet steel—becomes the subject of adaptation, and through an iterative process evolves into a unique device. Use of this adapted brake yields a surprisingly beautiful, self-supporting form that springs out of the nature of the material. Between the crisp straight lines and elegant curvature, ideal structural geometry naturally expresses itself throughout the surface of the sheet. As a monocoque thin-shell enclosure, One Fold is lightweight, durable, demountable and recyclable. As a sculptural form it is surprising and engaging from all angles. The possibilities of the One Fold principles were explored through a variety of projects. In all applications, the resulting assemblage of vaulted forms shares the juxtaposition of straight line and graceful curve that is further enhanced by the lustrous surfaces of stainless steel. One Fold is, in that sense, a solution but also a provocation to rethink our relationship, as architects, to materials and our means of employing them.

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1.0 design overview 1.1 Programatic research

Case study : Berlin Free University Case study : Rolex learning center- Sanaa

1.2 Tectonic Overview- The inhabitable column

Case study : Hollow Column Thracian Necropolis - Pomorie Case study : Sendai Mediatheque- Toyo Ito

1.3 Tectonic component : Folded Column

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1.1 Programatic Research

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Free University Berlin - Alexis Josic, Georgis Candilis, Shadrach Woods

Case study object

Informal spaces of learning- Courtyards and corridors and community exchange What I have learned

The balance between private spaces and communnal ones The role of the internal courtyard both as a space of gathering but as a source of light The interplay between the dark corridors and the luminous courtyards Vistas and visual connections between the different parts of the building, solving in one fell swoop almost all the problems of difficult orientation.

On a technical side: The importance of the metal finish and galvanization to avoid the rust Failure of the flexibility of the structure that was meant to be dismountable

Candilis, Josic, Woods Free University Berlin 1962 The original design of the Free University in West Berlin is a cautionary tale of a radical 1960s dream gone sour: a lightweight modular megastructure, with input by Jean Prouvé, intended to offer endlessly extendable and flexible space, which proved disastrously unresolved in the making. The main building of the Free University – built in successive phases since 1967 with the latest completed this year . The original design was by Team-X co-founders Georgis Candilis and Shadrach Woods in collaboration with their office partner Alexis Josic and German project architect Manfred Schiedhelm. Candilis-Josic-Woods sketched up a wide-spread, carpet-like structure of two- and three-storey high, modular spaces. The organisational structure with its covered streets and corridors, passing around inner courtyards, offices and auditoriums.All rooms and spaces within the basic spatial system were designed to be easily rearranged. If this could have been realised fully, all façade modules should have been demountable and able to be placed anywhere else in the building, turning it into an ever-changing machine for all future (spatial) needs the university might ever have.

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Rolex learning Center- Sanaa

Case study object

Spatial order What I have learned

‘One very big room, where people and programmes can meet together to have better communication,’.‘There are no walls to divide, so any programme can meet anywhere. It is more like a park.’Nishizawa The break with traditional bouderies - The boundless nature of this single volume space The main entrance at the center of the plan Informal attitude to occupation and circulation

Sanaa Rolex learning Center 2010 The construction of this building does of course deserve detailed scrutiny, with its 20,000m² footprint defined by an incredible low-slung concrete shell, anchored to a single-storey basement by 70 pre-stressed cables, and poured as a single element in just two days. The principal entrance lies at the centre of the plan, leading directly into a café and food court that occupy the lowest contour of the internal terrain. From here, two ridges rise up to cut across the space; one to the west that shields a 600-seat auditorium (which has its own entrance patio when screened off and used in isolation) and one to the east that bifurcates to form two peaks, one for the library to the north, the other for a formal restaurant to the south that occupies the highest point on plan from where the spectacular aspect across Lake Geneva gives views of Mont Blanc on a clear day. It is undeniable that for some people the contours may prove too steep - in places reaching a slip-inducing 30° pitch that cause most to shuffle down tentatively. This necessitated the provision of accessible ramps, steps and platform lifts that on the whole have been well integrated with terraces. These provide level places to study or meet. Other measures, such as the tactile floor track required to help those with impaired vision navigate the interior, also pale into insignificance when actually walking through the space. As intended, the strongest sensation that persists is the mesmerising effect of constantly shifting views, animated as horizons rise and fall in resonance with the mountainous landscape beyo

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1.2 Tectonic Overview- The Inhabitable Column

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Case study: Hollow Column- Thracian Necropolis- Pomorie

Case study object

Hollow column What I have learned

Unusual feature, the column in the middle of the hall rises up to the dome and blends with it in a way that makes you think that you are standing under the cap of a giant mushroom.

The column is hollow, with diameter of 3.30 meters in its center and inside it there is a staircase leading up to the top of the mound.

The light feature of the column : Thracians did believe in the unification of light and darkness. Symbolism of daylight introduced into the gloomy hall through the column.

Hollow Column Thracian Necropolis Pomorie The antique beehive tomb in the town of Pomorie is situated to the west from Pomorie, close to the road for Burgas. The tomb dates back to the 2nd – 3rd century AD. As a rule, the ancient tombs of Bulgaria were built in the latter centuries of the 1st Millennium BC for the nobles of the independent Thracian tribes. These tombs were built of stone, and had quite a simple structure. Covered by mounds, they had a corridor and, usually, one claustrophobically small burial chamber which could be either rectangular or round. There could be antechambers or additional rooms. The Pomorie Tomb is built of red bricks.

The mound covering it is an unusual elliptical shape and has impressive proportions – the axes are 63 and 53 metres. A 22-metre corridor leads from the entrance of the tomb to a circular chamber which is bigger than anything else found in Bulgaria, with a diameter of 12 metres. Five niches adorn the walls, another strange feature not seen in other Thracian tombs. Its architecture and construction impress visitors even nowadays due to its perfect implementation.

Many architects from the entire world study the tomb in order to find the secret of its mushroom-shaped dome. It was declared an architectural and constructional monument in Issue 35 of the Stage Gazette of 1965. Archaeologists and historians are still uncertain why it was built in this manner, and by whom.

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Case study : Sendai Mediatheque- Toyo Ito

Case study object

Hollow columns - construction and spatial organisation What I have learned

Honeycombs slabs, with steel plates with ribbing spaced in between, which allows for a far broader span than conctrete The tubes serve as vertical transports and energy core connections, housing elevators, stairways, ducts and cables Almost random placement of the tubes in plan and the varying floor heights for each floor Non traditional spatial organisation and treatement of bounderies

Toyo Ito 2001 Sendai mediatheque No structural facade, therefore transparency of the design. 3 basic architectural elements: plates(floors) tubes(columns) and skin (facade exterior walls) additional elements: exterior walls, partitions, doors, elevators, stairways.

The construction system ressemble the corbusier domino in its use of flat slabs and columns. But no concrete ones but honeycombs slabs, twin steel plates with ribbing spaced in between, which allows for a far broader span than conctrete. Moreover, the columns are hollow bundles of steel pipes, each with its own tubular shape ranging on diameer from 2m to 9m. And while each of these tubes is circuar in cross section, the centers shift from top to bottom so that they tread between floors at an angle.

These various hollow tubes serve as vertical transports and energy core connections, housing elevators, stairways, ducts and cables. Glass covered tube serve as air ssupply and exhaust flues , while also conduction natural light down to the lower levels. Almost random placement of the tubes in plan and the varying floor heights for each floor. The intent is not toward an industrial productivity or spacial uniformity but rather towards a specific uniqueness as seen in the as seen in the treatement of tube.

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Plate+tube+skin

The core: become a continous entity that tends to form an object rather than Structure.

The Combination of the structural elements allows to take on all sorts of porosity and form.

No shear walls+ tube columns= facade flexibility+ transparency and light

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Honeycombs slabs: twin steel plates withribbing spaced in between, which allows for a far broader pan than concrete.

The distribution of force around the tubes and in middle of the floors differed too greatly,so the ribs were made to radiate out from the tubes.

The result is that the distribution of force is not uniform throughout the slabs, so different spaces have different dynamics, a clear indication via structural analyses of the specifications of the various spaces on each floor. Inroducing the tubes made the floors non uniform, causing a ripple effect, which brings a fluidity to space.

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tubes: the columns are hollow bundles of steel pipes, each with its own tubular shape ranging on diameer from 2m to 9m. And while each of these tubes is circuar in cross section, the centers shift from top to bottom so that they tread between floors at an angle. These various hollow tube s serve as vertical transports and energy core connections, housing elevators, stairways, ducts a,d cables. Glass covered tube serve as air ssupply and exhaust flues , while also conduction natural light down to the lower levels. Almost random placement of the tubes in pan and the varying floor heights for each floor.

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1.3 Tectonic components: Folded Column

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2.0 material study 2.1 Metal forming

Case study: Porshe Pavillion- CIG

2.2Manufacturies visits

Morgan Motors Factory James Capper Studio Angler metal bending

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2.1Metal Forming

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Fabrication process : Panel Beating

Wood or nylon mallet Metal workpiece

Metal workpiece Wood or nylon chaser

Engineer’s hammer

Bag of sand or metal shot Epoxy or steel Jig

Dishing into a sandbag

Jig Chasing

Wheel

Steel plannishing hammer

Metal workpiece Steel dolly or dome

Performed metal workpiece Anvil

Wheel forming

Planishing

Panel Beating Process

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Fabrication process : Superforming

Cavity forming

Stage 1 : Preheated sheet loaded

Stage 2 : pressure applied

Bubble forming

Stage 2 : Vaccum Applied

Stage 1 : Preheated sheet loaded and blown

Backpressure forming

Stage 1 : Preheated sheet loaded

Stage 2 : Pressure applied

Diaphragm forming

Stage 1 : Preheated sheet loaded

Stage 2 : Pressure applied

Superforming Process

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Case study: Porshe Pavillon

Case study object

Curved sheet metal forming What I have learned

The envelope building is similar to the monocoque type construction used in lightweight construction in the automotive and aircraft industries. It has a supportive function. 620 stainless steel sheets have been welded together with reinforcing ribs, prefabricated in a shipyard in Stralsund and assembled on site.

Central Stall manufactured the assembled envelloppe in their factory and disasembled it then before shipping to Volvfburg where it has been reassembled.

When close to the structure the assembly lines are slightly visible through the shaddows of the seams on the steel.

The cost of such a structure with this manufacturing process is very expensive.

HENN architects Volvsburg 2012 Curving lines and exciting bends make the Pavilion a dynamic yet reduced sculpture with its characteristics derived from the Porsche brand image. A mattefinished stainless steel cladding forms the flush envelope of this vibrant structure, creating the impression of a homogeneous unity, whilst creating a continuously changing appearance depending on light and weather conditions.

On its entrance side the pavilion juts out for a total of 25 metres above the water surface of the lagoon in front.

Under the large, asymmetrically shaped roof a sheltered external space opens up with seats for several hundred visitors, being optically connected to the surrounding landscape and forming its own acoustic enclosure. The architecture and landscape, interior and exterior, roof and façade are designed as a uniform, flowing continuum, while the exterior of the pavilion designed by WES LandschaftsArchitektur has been integrated into the overall concept of the theme park. Inside the pavilion a concentrated space opens out to provide a tangible experience of the Porsche sports car brand and its history. The elliptically curved ramp takes the fundamental dynamic principle of the architecture and leads visitors down to the presentation area.

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Ribbing structure

Assembly seams are slightly visible

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2.2 Manufacturies visits

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Manufactury visit : Morgan Motors Compagny

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The forming capacity of aluminium with having to press shape it which is too cost intensive.

The project is investigating metal folding architectural elements.

Metal folding as a way to achieve a mode of fabrication that can create differenciation with low tech instruments .

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Manufactury visit : James capper studio - metal sculptures

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Manufactury visit : Angler factory - Tube and section bending, metal braking

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3.0 fabrication part i - cut, score, pattern 3.1 The cut and the score 3.2 The pattern

Case study: Industrial Origami Test - Cnc router settings

3.3 Hinging the fold

Case study: Test - Flexibility

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3.1 The cut and the score

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Fabrication process : CNC machining

Track for 2 axis movement Dust extraction unit

Various interchangeable tools X, Y and 2 axes

Rotating tool Caroussel

Track for X and Y axis movement

Guard

Cutting tool

Chuck and spindle Workpiece Vaccum clamp

Table

3 axis CNC with tool caroussel

Track for Z axis movement

Track for X and Y axis movement

Pivoting head

Pivoting router

Chuck

Cutting tool X, Y and Z axes and 2 axes of rotation

Table

Workpiece Vaccum clamp

5 Axis Cnc with interchangeable tools

CNC Machining Process

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235

400

R190

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42 Ø217

Flat Aluminium sheet with creases marks

Cutting and Scoring the pattern follwing a mountain valley scheme

metal folding- cnc routing process

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Test : Cnc cutting and scoring settings

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3.2 The pattern

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Case study: Industrial Origami

Case study object

The crease patterning What I have learned

When folded metal sheets tend to break. The equilibrium between the amount of material to leave and remove is very delicate. Thus, the patternig allows to keep some parts of the folds uncut and thus strengthen it Also, Industrial Origami’s fold-and-build method eliminates the measuring, cutting and welding and bolting that usually goes into producing parts. The company says it can save manufacturers anywhere from 20 to 50 percent on materials, and 25 to 45 percent on labor The parts travel as flat sheets, and so are easier to handle and cheaper to ship The performations can present an opportunity to be a source of light

Max Durney 2002 Institute of aircraft design- University of Stuttgart Founded in 2002 by manufacturing designer Max Durney a, Industrial Origami has come up with a strong, simple, brilliant, and relatively inexpensive way to build things: By precision folding sheets of aluminum and steel. An Industrial Origami designed product starts as a sheet of metal that has been pre-shaped and perforated along the folds with the company’s signature smile cuts. Those sheets are sent to shop floors where assemblers fold them into the working forms. .

Prepping parts with a coat of paint before they are folded is also much faster and easier than painting built or assembled components. “Industrial Origami profoundly changes the way products are designed and manufactured,” said Patrick Sheehan, a partner at the London-based Environmental Technologies Fund, one of the first groups to invest in the company. Industrial Origami has raised $32 million in venture funding and it is hoping to convince investors to put another $20 million more into the company this year.The technique provides parts with surprising strength, in addition to the benefits listed above. Industrial Origami has already lined up big-name clients like Bentley Motors and Whirlpool and has some 254 patents to date. Production method geeks can read more about the process, which is also applicable to certain plastics and composites 63

Test : Folding the pattern

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12.81

3.35

19.50

23.441

16.890 2.74

9.77

15.26

Interstitial distance 6.4 mm

11.214 1.62

5.76

9.00

Interstitial distance 2.6 mm

11.214 0.66

9.24

10.56

Interstitial distance 2.6 mm

11.214

4.86

12.81

19.50

Interstitial distance 2.9 mm

11.214 2.74

9.77

15.26

Interstitial distance 7.6 mm

11.214 1.62

5.76

9.00

Interstitial distance 4.6 mm

13.362 0.66

9.24

10.56

Interstitial distance 4.2 mm

Interstitial distance 4.5 mm

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4.96 2.13 4.96 2.13

Interstitial distance 2.1 mm

MATERIAL: PLAIN ALUMINIUM 0.5 MM CUT DEPTH: 0.5 MM TOOL: VDRILL

2.13

4.96

4.96

2.13

Interstitial distance 0.1 mm

4.90

4.90

Interstitial distance 2.1 mm

0.15

0.10

0.30 0.45

0.25 0.40

TOOL: VDRILL

0.20

CUT DEPTH: 0.5 MM

0.35

MATERIAL: PLAIN ALUMINIUM 0.5 MM

cut depths

0.05

Interstitial distance 5.1 mm

crease bending

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MATERIAL: PLAIN ALUMINIUM 0.5 MM CUT DEPTH: 0.5 MM TOOL: VDRILL

surface flexibility

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Test : Patterning and flexibility

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3.3 Hinging the fold

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Fabrication test

purpose size material

Facing the failure of folding a complex pattern, this test would be looking at the hinging the creases of the folds to create a deployable structure 500 mm x 500 mm x 0.5 mm Aluminium sheet, cnc router, Hinges

process description Investigating the differnet hinging option that could support the motion of the folds conclusion

A complex system that could be implemented for small portions of the project but does not respond to the brief ’s fabrication system.

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Case study : Sogame- Ori

Case study : Z folding mechanism

Lady bug wing 2017 University of Tokyo

Sogame- Ori 2019 Yamanaka laboratory

A group of researchers at the University of Tokyo and their collaborators have figured out how ladybugs fold their wings by transplanting a transparent artificial wing onto the insect and observing its underlying folding mechanism. The study’s findings, which help explain how the wings can maintain their strength and rigidity during flight, while becoming elastic for compact folding and storage on the ground, provide hints for the innovative design of a wide range of deployable structures, from satellite antennas to microscopic medical instruments to articles for daily use like umbrellas and fans.

Ladybugs are highly mobile insects that can switch between walking and flying with ease and speed because they can quickly deploy and collapse their wings. Their wings consist of the hardened elytra, the forewings with the familiar spots, and the soft-membrane hindwings used for flight, which are covered and protected by the elytra.

Previous studies have suggested that up-and-down movements in the abdomen and complex origami-like crease patterns on the wings play important roles in the folding process, but how the simple motion produces such an intricate folded shape remained a mystery. Ladybugs close their elytra before wing folding, preventing observation of the detailed process, and as the elytra are essential elements for folding, they also cannot be removed to reveal what lies underneath.

To study the folding mechanism and structure, a Japanese research group constructed a transparent artificial elytron from ultraviolet light-cured resin—often applied in nail art—using a silicon impression of an elytron they removed from a Coccinella septempunctata spotted ladybug, and transplanted it to replace the missing forewing.

Sogami- Ori is a method of producing collapsible or folding structures often utilized in the design od space stations. It can fold down something very large into something extremely small. The Yamanaka laboratory took Sogame- Ori one step further by manufacturing the structure in one piece, including the hinges. In this technique the whole object is manufactured in its collapsed form and requires no assembly after printing. Current £D printers cannot produce objects larger than the printing vessel, because the manufacturing process is carried out inside a powder container within the printer itself. The Yamanaka laboratory’ Sogame-Ori experiment illustrated that objects otherwise too large to print could be produce in collapsed form and then folded. In showing this we have expanded the possibilities of additive manufacturing beyong conventional limitations.

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4.0 fabrication part ii - fold 4.1 Robotic folding

Case study: Robofold Test -

4.2 Manual folding Test Test Test -

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Fabrication process : Press Braking

Hydraulic ram

Punch Workpiece (blank)

Die

Stage 1 : Load

Stage 2 : Air bendind

Bottom bending

Press Braking Process

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Goosneck bending

4.1 Robotic folding

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Case study : Robofold

Case study object

Robotic curved folding What I have learned

The metal is bent and precisely formed, a replica of what is displayed on the screen “You can program variations in up-front and say what are the parameters that you want to vary No molds are needed prototyping and manufacturing manufacture could be using the same equipment The curvature in the metal sheet when folded adds so much rigidity that you can use a sheet material that is less thick.

The process does not stretch the material like a standard press does, so holes can be pre-drilled and trimming is not needed.

The speed of the process is slower than that of pressing, It is a single stage process, whereas pressing could involve several stages before being drilled and trimmed by a 5-axis laser-cutter.

Robofold compagny 2010 This process is capable of creating individual cladding panels — something that until now has been too expensive and time consuming. The system works off a plug-in for designs built in Rhino 3D CAD with the software coding developed

by Robofold. The designs are translated into folding simulations in the King Kong software. In turn these results are linked to the Godzilla robot software, to simulate robots folding, before the physical folding begins. The folding software can be purchased on its own, but Robofold has also developed 3-axis CAM software, 6-axis CAM software, and other robot inputs to make best use of the hardware it drives. For the construction team, the individual nature of each programmed sheet being formed by robots at the building site means any last minute changes can be quickly and easily rectified. Metal is best for bending, typically using 1.5mm aluminium, cut with the CNC router in the factory. It can also work laser cut steel or stainless steel up to 1.5mm. The steel can be finished with paint or dipped in zinc, while aluminium should be anodised; giving a range of options for finishes. Accuracy of the panel is defined in the cutting of the flat sheet.

Working with desktop paper printers to verify and tweak sheet designs allows mini versions of an architect’s design to be scaled up for production in metal. If the future is to grow more dependent on mobile, localised factories then methods of onsite production like these offered by Robofold are destined to lead the way.

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Two Robots folding in alternance using succion cups

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Test : Folding through robotic pulling

Folding through Robot pulling 82

Fabrication test

purpose

size material

Trials to transpose the patterns of folding from the manual technic to a robo tised one that could enable the fold to reach a big scale 500 mm x 500 mm x 0.5 mm Aluminium sheet, cnc router, Kuka Robot, Custum made hook tool

process description

Using the robot hand supplemented with custum made tools to fold a 2D patterns into 3 dimetional shape

conclusion

This is showing the complexity of the folding that depends on the material, the crease pattern but also that relies on a feed back loop hard to replicate with the robot.

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Anchor point bolting

Scored pattern

Securing pulling points

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Custum made pulling tool for the robot

Hook and cable pulling system

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Folding Axis failure

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The lifting points are placed on the four corners of the aluminium sheet.

The alumimium sheet is secured and botlted at its center on the robot table.

While pulling the sheet folds in two along of of the crease pattern instead of folding into four.

Even if anchored to the table, the sheet is ripped off from its center. Throughout the pull the fold only happened on one axis.

87

Anchoring point

88

The lifting points are placed on the four corners of the aluminium sheet. Four additional lifting points are placed between the four creases of the aluminium sheet pattern. This experiment is made with eight lifting point.

The alumimium sheet is secured and botlted at its center on the robot table. While pulling all the pulling points are lifted but not symetrically.

While pulling the sheet is twisted and again folds along a horizontal axis that crosses the anchor point.

The twisting is intensified and the pattern does not impact the folding. Even if anchored to the table, the sheet is ripped off from its center.

89

90

The eight lifting points are placed around the anchor point at the center of the aluminium sheet.

The alumimium sheet is secured and botlted at its center on the robot table. While pulling all the pulling points following the central part of the creases.

While pulling the sheet folds along a horizontal axis that crosses the anchor point and twists slightly

The pattern does not impact the folding anymore. Even if anchored to the table, the sheet is ripped off from its center.

91

4.2 Manual Folding - Topography

92

Fabrication test

purpose size material

Understand the forces required to fold a metal sheet along a crease Mapping the trajectory of the folding motion 125 mm x 125 mm x 0.5 mm Aluminium sheet, cnc router

process description Top view video recording of the folding process of patterns increasing in complexity conclusion

This test is meant to infrom on the way folding occurs, which motions -pul ling, pushing or twisting- happens and how they relte to certain types of crease pattern. The sequence that is reconstituted shoud then later be used to gene rate a code to feed the robotic arm.

93

94

95

96

97

Test - One continuous curved crease

98

The folding pattern of this aluminium sheet is a continuous curved line situated near the edges of the piece.

Placing hands on both sides of the curve starting from the end of the line, the space available between the crease and the cut is narrow. Folding slowly

Keepimg folding while sliding the location of the gripping alomg the crease toward the corner.

Redo the same operation on the second edge.

Placing hands on both sides of the curve starting from the end of the line. Folding slowly again.

Repeat third step. Keepimg folding while sliding the location of the gripping alomg the crease toward the corner.

Holding the metal sheet at its center and placing both thumbs symetrically.

Pushing with the tumbs on the center of the piece and pushing from the back with the rest of the fingers on the aisles of the sheet under the crease.

Checking the fold on the other side of the metal sheet and decide wheter you need to keep on repeating the previous step.

99

Test - One continuous crease composed of a straihgt crease and a curved curved

100

The first step is looking at the scored pattern in order to understand or to project the folding pattern in 3D

The crucial part of the fold process of this model lies in the connection point between the straight crease and the curved one

Holding the sheet at the intersection between both lines and folding the upper part of the curved crease

Rotating the aluminium sheet then applying pressure on the intersecting point

Flipping back to the scored face and gripping the sheet from both side of the straight line making a slow back and fort motion on this axis

Gripping the sheet from both sides of the curved line making another slow back and forth motion on this axis

Holding the sheet with both hands under the curved crease aiming for the centroid placing the thumbs

Pressing with the thumbs on this area while pushing back with the rest of the finger in a backward motion from the back of the sheet

Holding the sheet from both sides of the straight line and placing the thumbs at the intersection between both lines

Applying a pressure on the crease starting from the intersection to fold the straigh tline

Pinching the intersection and applying a pressure on the curved crease area adjacent to it in order to help fixing the direction of the fold

Holding the sheet from one side of the curved line

Pushing the other side toward the bottom along the curved line bottom up until the intersection

Pushing with the tumbs on the center of the piece and pushing from the back with the rest of the fingers on the aisles of the sheet under the crease.

The intersection of both line presents a resistance wheter you try to fold along the curved crease or the straight one.

We notice a slight deformation at the point of intersection as the fold lines pushes the metal sheet grain in different directions.

101

Test - Four creases composed of two valley lines and two mountains

102

The metal sheet presents four scored pattern that depart for one sigle point .

The creases are made on both sides of the aluminium sheet thus presenting the configuarion of valley and mountai scoring.

Placing handes on each part of one of the external crease, fold it partially staring from its middle.

Turning the metal sheet on the other side and placing hands symetrically along one of the internal creases

Folding along this line staring from its middle going along the crease.

Grapping both sides of the external folds fingers all on the top but the tumbs that are placed on the bottom of the sheet.

Exerting a motion from outside in almost twisting the external creases in order to reinforce the fold.

Holding one part of the sheet and with the other hand rotate the extenal fold

Folding again the first external crease going from the edge toward the intersection point

Folding the second external crease going from the edge to the intersection point

Grapping the area outside of the pattern placing the fingers along the crease and pushing the sheet toward the bottom.

The intersection fold lead to the deformation of the metal sheet show a pattern of continuty of the bigger external crease.

Trying to fix the deformation , holding the aluminium sheet from each sides of the creases

Applying pressure with the thumbs on the deformed parts and a counter pressure with the fingers placed on the bottom assessing the needs by eye.

Grapping the area outside of the pattern placing the fingers along the crease and pushing the sheet toward the bottom.

The pattern of the crease have been projected outside of the drawn lines on the metal sheet as the folding gave the metal sheet directionality.

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Test - Straight and curved creases

104

This piece is composed of 4 folding lines , curved and straight

On each side of the metal sheet lies two creases

Deciding on the folding strategy and which creases should be folded first

Starting folding the central straight line pattern partially

Placing hand gripping the outer part of the curved crease.

Applying pressure with the thumbs along the crease.

Keep on folding while rotating the aluminium sheet.

Pinching the central Fold by pushing the thumbs in an inward motion.

Gripping the sides of the triangle like crease and twist it .

Redoing the same operation on the symetrical side.

Pushing with the thumbs on the intersection point of these two last creases.

Gripping the sheet along the central crease and rotating the hands in a joining like motion.

Rotating the sheet while pinching with the fingers along the curved crease.

Keep on repeating the same operation until the result is satisfyng and the fold is homogemous.

Gripping the edges of the sheet and reinforcing the main fold through twisting the edges with the thumbs.

Pressing along the triangle like curves until reaching the intersection point.

105

Test - Two curved creases valley and mountain

106

The folding pattern on the aluminium sheet is composed of two creases

The second crease is place on the bottom of the sheet forming a montain and a valley scoring

From the outer line, start the folding process with a gentle pressure

Placing the thumbs in the center of the main crease pattern

Turning the aluminium sheet and holding it wit the finger inside and along the crease patter.

Rotating motion in order to fold the curved

The first crease is folded assessing if there is need to fold is more or stop depending on the achieved shape.

Rotating the sheet on the other side to fold the second crease.

Placing one hand in the middle of the crease area, the other hand on the top of the crease previously folded . Apply a ligh pressure to mark the fold.

Placing the hands thumbs in the middle and push toward the bttom the central area while pushing up with the rest of the fingers.

Repeating the same operation on the edges of the crease.

Rotating the metal sheet and gripping the edge of the piece

Sliding the fingers in a pinching like motion to accentuate the curvature of the edge.

Holding one side of the fold with bot hands and accentuating the crease through small pressures.

Holding the second side of the fold with bot hands and accentuating the crease through small pressures.

Reshaping slightly the outer crease.

The result does not show any error or deformation.

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Test - Six folds composed of valleys and mountains

108

This piece is composed of 6 crease lines located on both sides of the line, valleys and mountains.

Placing the hands on the central curve, one hand being immobile

The other hand rotates to make the fold along this axis

Switching hands, repeat the operation , folding the second central curve.

Holding the outer part of the previously folded curves , Twisting the metal sheet and intensyfying the fold.

Placing the thumbs in the center of the third crease and fold along the line, one hand pushing and the second hand counter pushing

Rotating the aluminim sheet keep on applying pressure with one hand pushing and the second hand counter pushing

Repeating the two previous operations on the symetrical part of the sheet creasing the fourth line.

Holding the sheet from bot side of the external creases and squizing toward the center of the piece.

Pulling of part of the sheet while pushing on the edges of the folds

Pulling part of the sheet while pushing on the edges of the folds

Rotating the aluminium sheet in order to fold the valley creases

Placing the hand thumb on the center of the valley crease..

with one hand moving the aluminium sheet while pressing with the thumb on the center of the folding target area.

Placing both thumbs under the crease applying pressure while counter pressure on the side with the rest of the tumbs.

The folding did not present any defect.

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4.3 Manual Folding - Column

110

Fabrication test

purpose size material

process description conclusion

Understand the forces required to fold a metal sheet along multiple creases to generate a column like design 300 mm x 300 mm x 0.5 mm Aluminium sheet, cnc router Top view video recording of the folding process of patterns of differents column patterns This test is meant to infrom on the way folding occurs for a specific design with the variation of one parameter- the fold radii.

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112

Column type I Folding

creating curvilinear structures through torsion and patterning

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30 ° angle symmetric torsioned structure

15 ° angle asymetrc torsioned structure

15 ° angle single side torsioned structure

structure without any torsion applied

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Column type II Folding

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118

It can have different parameters modified to impact its shape, height or concaveness.

The base shape - The footprint of the column The crease readius - impact the footprint of the column and the slenderness as well as the possibilty to have a livable column core The crease length - impacts the height of the column The creases symetry or asymetry- nables to build up different floor slabs and height The positioning and number of creases- enables the creatind of circulation and their extension into vaults or partitions 119

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VARIATION OF THE CREASE LENGTH AND SYMMETRY OF THE122 CREASE ANGLE

SLC105ACCR70-60

ALC105-125ACCR70-60

ALC105-125ACCR70-60

ALC105-125ACCR70-60

ALC105-125ACCR70-60

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VARIATION OF THE OCCULUS RADIUS

VARIATION OF THE OCCULUS RADIUS

VARIATION OF THE CREASE ANGLE

VARIATION OF THE CREASE ANGLE

VARIATION OF THE OCCULUS RADIUS VARIATION OF THE CREASE ANGLE VARIATION OF THE CREASE LENGTH SYMETRY VARIATION OF THE CREASE RADIUS

126

VARIATION OF THE SYMMETRY OF THE CREASE ANGLE

127

128

129

Test - Symetrical column pattern

130

The crease pattern is constituted by four curved lines with the same radius

Placing the hands on each side of the creases start by lightly fold the linear segments of the curves

Do the same operation consisting of a twising motion for all the curves

We notice a light deformation

Operate another round of twisting gently

Rotating the aluminium sheet, the creases starts to be marked.

Placing the thumb in the center of the sheet holding it while raising one of the area between the folds

Redo the same operation with the adjacent fold

With the fingers , twist and pull along the crease

Repeating the same operatino for each side of the sheet

gripping the edges and twisting to strenghten the fold

pulling towards the center of the sheet

With both hand gripping each part amd rotating the hands in a assymetrical motion giving shape to the curvature of the flange.

Repeating the same motion successively until the appropriate folding is reached.

Gripping two creases at a time and proceed to a pinching like motion

The result presented some slight asymetries due to the difficulty of applying the exact same pressure along each crease.

131

Test - Asymetrical column pattern

132

The crease pattern is constituted by four curved lines that have different radii.

Placing hands on each side of the the scored pattern, given the fact that these are not symetrical, thumbs need to be positionned on each area

Hoding position of one hand and pushing toward the bottom with the other hand.

Placing hands on 2 other areas and repeat the folding securing position with one hand and folding with the other

With both hands, gripping opposite areas and move one hand toward the other in a closing motion

Grip the edge and twist each of them simultaneously to crease the edges

Turning the aluminium sheet and Placing the hands thumbs in the bottom

Rotating the hands in a twist like motion pushing with the fingers toward the bottom

Giving curvature with the thumbs

Doing the same operation with each area one after the other gently creating the fold through repetitions

Come back to the edge to redefining them as these weak area deform easily

Griping the edge defyning the final curvature with the fingers through twisting and pushing

Griping the edge defyning the final curvature with the fingers through twisting and pushing

Placing hand around two creases

Pinching strongly to secure the shape

The final result does not show imperfections and respected the geometry

133

5.0 fabrication part iii - cast 5.1 Folded metal formwork

Case study: traditional steel formwork Test- Planar cast Test - Shotcrete Test- Concrete Slip cast

5.2 Reinforcement strategy- hot wire foam cutting Workshop Test - Hot wire foam cutting Test - Foam formwork Test - Foam reinforced metal formwork

134

5.1 Folded Metal formwork

135

136

Test - Planar cast

Fabrication test

purpose size material

process description conclusion

Trials to cast on top of folded aluminium sheets that become a concrete formwork .

150 mm x 150 mm x 0.5 mm Aluminium sheet, cnc router, Concrete.

Using the folded metal sheets as a formwork to cast concrete This method offers divers advantages: the metal formwork can become a lost formwork being the surface finish. As well the cast itself could be used as a formwork relying on as a cast on cast method.

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concrete cast

polypropylene layer

Folded aluminium formwork

Test - Cast on Folded Aluminium sheets

139

140

The cast piece present a texture finish due to the choice of avoid a very wet casting slip

The metal formwork and the polypropylene sheet had to be glued to avaoid any wavy effect of the geometry

The cast piece presents an uneven edge, in order to enhance this a two parts mold would be necessary

The curvature of the initial folded aluminium sheet was respected, britle corners.

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142

Test - Shotcrete Formwork

143

144

Fabrication process : Tube and section bending

Static rotating roller Metal section

Dynamic rotating roller Static rotating roller

Rotating cores ( spindles)

Ring Rolling Process

Rotating die

Metal blank

Pressure clamp Rotating clamp Mandrel

Stage 1 : Load

Stage 2 : 90 degree bend

Mandrel Bending Process

145

Fabrication test

purpose size material

process description conclusion

Scenario to cast using a shotcrete technic on a folded mold composed of eight parts joined together through extra flanges.

400 mm x 400 mm x 0.5 mm Aluminium sheet, cnc router, folded columns, Concrete.

Casting on the surface of the folded column To use this method the folded aluminium sheet needs to be redesigned and upgraded with additional flanges as a joining system.

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149

Cement and damp aggregate are thoroughly mixed, or premixed, and prebagged cement and aggregate are fed through a premoisturizer. The cement-aggregate mixture is then fed into the gun. The mixture is introduced into the delivery hose via a metering device such as a feed wheel. Compressed air is added at the gun and the mixture is carried through the delivery hose to the nozzle. The nozzle is fitted inside with a perforated water ring through which water and admixtures are introduced under pressure and intimately mixed with the other ingredients as they go through the nozzle. The concrete is propelled from the nozzle at high velocity onto the receiving surface.

Description of guns. Dry-mix guns are divided into two classifications, the double chamber gun and the continuous feed gun, each of which is capable of delivering mixtures in a wide range of consistencies.

Double chamber. The first gun developed was the double chamber or pot type, introduced in the early 1900’s. Although the material enters the upper chamber in batches, the valve arrangement is such that the discharge from the lower chamber is continuous. Until recent years, this gun had been used only for mortar mixtures and the production rate was low, but larger, high-production units which will handle coarse aggregate up to about 3/4 inch are now available.

Continuous feed. The continuous-feed gun was introduced about 1960. Most of these guns will handle mortar or concrete mixtureswith aggregate up to about 3/4-inch and will produce shotcrete at production rates up to 2 cubic yards per hour. b. Plant layout. A typical plant layout for a dry-mix shotcreting operation, including air and water supplies, gun, delivery hose, and nozzle.

Pre-bagged shotcrete material

Predampener

Shotcrete gun

Nozzleman

Air compressor

Reinforced steel Wate supply

Nozzle

Rebound

dry mix shotcrete process

150

Cement, aggregates, and admixtures (except accelerators) are thoroughly mixed. The mixture is fed into the gun and propelled through the delivery hose to the nozzle by compressed air or pneumatic or mechanical pumping. Air is injected at the nozzle to disperse the stream of concrete and generate the velocity for shotcrete placement. a. Description of guns.

Pneumatic-feed. In the pneumatic-feed equipment, the premixed mortar or concrete is conveyed from the gun through the delivery hose to the nozzle by slugs of compressed air.

At the nozzle additional air may be added if needed to increase the velocity and improve the gunning pattern. This equipment can handle mixtures of a consistency suitable for general shotcrete construction, using mixtures containing up to 3/4-inch aggregate. Guns with a dual mixing chamber and a two-way valve allow mixing of materials and a continuous flow operation.

Positive displacement. In the positive displacement equipment, the concrete is pumped or otherwise forced through the delivery hose without the use of compressed air. Air is injected at the nozzle to disperse the stream of concrete and impart the velocity necessary for shotcrete placement. Positive displacement delivery equipment requires a wetter mixture than pneumatic-feed equipment, and the velocity of the shotcrete being applied is lower.

It is difficult to apply shotcrete to vertical and overhead surfaces by this method unless a suitable accelerator is used. This equipment can also satisfactorily shoot material containing 3/4-inch aggregate.

Ready mix truck

Concrete pump Nozzleman

Reinforced steel Air compressor

Nozzle

Rebound

wet mix shotcrete process

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154

Test - Concrete slip cast

155

Fabrication test

purpose size material

Trials to cast between two folded aluminium sheets that become a concrete formwork .

400 mm x 400 mm x 0.5 mm Aluminium sheet, cnc router, folded columns, Concrete.

process description

Using the space between two folded metal sheets as a formwork to cast concrete

conclusion

This method offers reached a limitation, the need to have supporting elements to stop the deflection of the mold under the weight of the concrete slip. What leads to the next experiment.

156

Pre- cut and folded edges to secure position Two pieces mold, intended for a slip casting

The cast is slipping towards the bottom what affected the geometry failure

Imprint of the second par of the mold

The Bottom part of the mold deformed under the presseure of the cast

The cast once dry before demolding, we can see the uneveness of the piece

157

Casting failure of replicating the initial geometry on the four edges

Imprint left by the the second part of the mold

Flattened curvature due to the weight of the cast

Test - Concrete slip cast column type II

158

Two parts mold made with edges to secure the position of the aluminium formrwork

The upper part was not heavy enough to enable a clear imprit of the column form

Finish of the cast, some edges show a good definition

The geometry of the bases of the column changed because of the self weight of the cast exerted on the thim alumimium sheet , 0.5 mm

159

Good definition of the edges of the column cast

Test - Concrete slip cast column type I

160

Good definition of the edges of the column cast

The sides at some part deformed against the expansion of the concrete

The alumimium formwork despite the dirst of the concrete could be left as a fnish layer if cleaned

The crease pattern has been cast accordingly to the folded geometry

161

5.2 Reinforcement strategy- hot wire foam cutting

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Fabrication process : CNC hot wire eps foam cutting

165

Fabrication process : Robotic hot wire eps foam cutting - Robochop

166

Test - Double curved Foam surface hot wire cutting

Hot wire Foam cutting 167

168

Test - Hot wire Foam Cutting

169

Opportunity to use the foam as a formwork

170

The modeling of the rounded top part could not be achieved

Perfect definition of the geometry and curvature of the column flanges

Success in hot wire cutting four supporting pieces according to the metal folded formwork geometry

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172

Test - Foam Formwork

Fabrication test

purpose size material

Casting in a robotically cut piece of foam 400 mm x 400 mm x 0.5 mm Kuka robot, Foam, Concrete

process description

Using the column existing geometry a foam model was fabricated. This experi ment uses the void with the foam model to cast a concrete column.

conclusion

The foam is not an accessory to folding but becomes the formwork itself. The drawings shows an alternative possibility of using a simplyfyied version that would be based on a single curvature column design , which can be easily industrialy manufactured at a big scale.

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Hot wire cut foam formwork

Missing geometry

Demolded concrete piece

Uneven edges

The concrete slip was not wet enough to reach all the parts of the mold

176

Initial Geometry overall respected if not taking account of the texture

The foam binded to the concrete cast affecting its finish

Test - Column casting in foam

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178

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180

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182

Test - Foam reinforced metal Formwork

Fabrication test

purpose size material

Trial to robotically cut piece of foam that can support the sides of the folded aluminium formwork.

400 mm x 400 mm x 0.5 mm Kuka robot, Foam, Aluminium sheet, cnc router, folded aluminium for mwork, Concrete

process description

Using the column existing geometry fabricate support element with the accor ding radius to hold the metal formwork while casting

conclusion

The cutting revealed very complicated but successfully worked after many attempts and with the help of the dpl team. A question remains on the hot wire cutting with the kuka robots as it presents limitation of size. As a prototy ping tool it did fill the purpose. Further research should be conducted on In dustrial Hot wire cutting of double curved shapes.

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Concrete column

Holding strap

Hot wire cut foam at specific angle

Spacers

Internal folded metal sheet

External folded metal sheet

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3 Inserting the metal spacers in the pre-cut hole

2 Adding the internal folded metal sheet

1 External folded metal sheet

CONCRETE COLU

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ut holes

6 Pouring the concrete mix

5 Holding with a strap

4 Placing the foam to perfect the folding and to keep in shape the alumium formwork

COLUMN - METAL FORMWORK CONSTRUCTION SEQUENCE

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6.0 fabrication part iv - breaking down the fold

6.1 Introduction

Case study: Arum sculpture

6.2 External flanges 6.3 Internal flanges

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Case study: Arum sculpture ZHA architectes

Case study object

Subdividing a column into parts due to the limitations of the metal sheets available sizes.

What I have learned

The number of pieces necessitates more connections and bolting The structure was wably and non strutural The respect to the initial geometry was respected but not the structural will For my geometry trial to divide the structure into the minimum number of elements possible- in respect to the material dimensions

Zaha hadid architects 2014 venice Biennale The largest piece of work to date created by this method was for Zaha Hadid Architects — the Arum sculpture for the Venice Biennale.

A six metre high, tulip shaped, self-supporting structure, the design was created with Robofold’s input and manufacturing service.

“We helped the Zaha team to develop their own software so that it would generate all of the data we’d need for production. “They were able to generate valid, folded surfaces, and then out them to us and we would automatically create the production data from it.” The sheets were cut in the UK and transported to the site in Venice where two robots were ready waiting to fold them.

Seeing the process in action was a big benefit for the Zaha Hadid team, although this did add pressure. “We still had them on site, changing their mind while we were building it!” Mr Epps explains. This problem only served to highlight the benefits of the process — new parts were swiftly modelled, cut and flown to the site, where the robots folded the new sheets without any mass reprogramming or delays. “I think it was quite daring of them to use us, as this was the largest piece we’d done to date. It’s a really cutting edge technology, but it shows that they’re a cutting edge practice to be able to embrace it.”

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6.1 External flanges

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Fabrication test

purpose size material

process description conclusion

Scenario to cast using a shotcrete technic on a folded mold composed of eight parts joined together through extra flanges.

400 mm x 400 mm x 0.5 mm Aluminium sheet, cnc router, folded columns, Concrete.

Casting on the surface of the folded column To use this method the folded aluminium sheet needs to be redesigned and upgraded with additional flanges as a joining system.

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Test - External flanges

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6.2 Internal flanges

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Fabrication test

purpose size material

In order to fabricate the column at a 1:1 scale, the aluminium sheet and thus pattern need to ne subdivided.

6000 mm x 6000 mm x 0.5 mm Aluminium sheet, cnc router

process description

Fragmenting the previous pattern into 8 parts thinking the additional parts needed to reassemble them into one model.

conclusion

This test is meant to inform on the constructability of folded structure on a big scale.

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Test - Internal flanges

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7.0 construction sequence

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Phase 1 - CNC router aluminium sheet cutting and scoring

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Phase 2 - Robotic hot wire eps foam cutting

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Phase 3 - transport to site

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phase 4 - foam assembly

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Phase 5 - Flat metal components folding against foam jigs

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Phase 6 - Aluminium mold parts assembly

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Phase 7 - Column components assembly and rebars placing

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Phase 8 - mould reinforcement, foam installation

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Phase 9 - Proping and casting

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8.0 accoustics

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Fabrication test

purpose size material

process description conclusion

Lookimg at the concrete finish as an accoustic tool 500 mm x 500 mm x 0.5 mm Concrete casts Understanding of the holes on the surface of a concrete cast can present an advantage when it comes to sounproofing.

Depending on the size of the holes that texture the concrete different types of sound waves can be caught. The idea is then to give the concrete cast the desired finish with the desired gaps depending on the types of the sound wave that we wnat to see absorbed.

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Test - Sound absortion

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9.0 structural simulation

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8.2 Creating an opening

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Total displacement

Deflection

Danger Level

Tension and compression

The total displacement helps to visualise the distribution of loads in the structure. Looking at the Deflection, we notice that the opening edge is the most affected area by the deformation. The Danger level shows risks of failure in the upper creases - green coloration. This level impacts the tension and compression. The structural viability of this strutture with opening is limited.

Simulation - 4 sides column

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Total displacement

Deflection

Danger Level

Tension and compression

The total displacement simulation shows that the top part of the column is subject to fracility, it is the main part that deflects and deform. The structure would not tolerate point loads in this area. The supported structure should channel then these loads towards the four sides upper creases to channel them toward the ground.

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8.1 Removing sides

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Total displacement

Deflection

Danger Level

Tension and compression

The total displacement shows that the loads distributed along the edges of the removed face represent the fragile areas. In fact in case of deflection, hthese are the parts that are deformed but mainly the upper edge. If Tihs geometry was to be used, a reinforcement strategy of this area should be considered.

Simulation - 3 sides column

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Total displacement

Deflection

Danger Level

Tension and compression

This structure seems quite stable and works well, in case of deflection the deformation is not as important as for other models . The most sensitive part would maybe be the creases that might necessitate reinforcement due to the nature of the material.

Simulation - 2 sides column

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Total displacement

Deflection

Danger Level

Tension and compression

This configuration is less stable than the [revious one even though they share the same number of faces. The positining of the face is clearly important and the prebious option - adjaent faces is more stable that this one- facing faces. The total displacement shows that the central part does not allow for load distribition and would significantly be deformed in case of deflection, The danger level shows as well the possibility of a structural failure at the creases This makes the upper part of the column not structural This option should be put on the side if intending to work as a strure.

Simulation - 2 sides column

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Total displacement

Deflection

Danger Level

Tension and compression

One single face component. This unit structurally performs well. The loads are distributed along the central part of the element. The sensitive parts that would be subject to deformation in case of deflection are the external edges.

Simulation - 1 side column

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9.0 conclusion

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Metal Sheet can be stamped by dies, and pressed with lots of force on expansive moulds. The ts project focus on metal sheet as a material to fold but at the same time as a fabrication technic that bridge between design , prototyping and manufacturing. Not only did the fold bring forth to the project, it also became its fabrication process.

From the cut, score and pattern stages, the conclusion is that a simple cnc router can definitly be an affordable way to insert the crease into the flat metal sheet. This method allowing the designer for changes and variations that were not permitted with the moulds. Water jet cutting or laser cutting are not necessary for a big scale unit, that does not need the highest level of finition.

The fold raised more questions and challenges. The robotic option became a failure, due to the complicated set of instruction used to do a curved fold. the hands’ s dexterity and human feedback loop seems to be at this moment necessary. The hot wire cutting offer an interresting and again quite affordable solution to fabricate both a jig to fold against but as well a resstraining device to cast in situ.

The folded slip cast mold system is a fabrication device that allowed to fabricate a curved column . It is a tool that can help the designer with the development of complex technical assemblies.

The folding presents future prospects as a big scale fabrication method that should be further researched. It could be a possible solution to face the invariance of the production of some components and shapes that require traditionaly moulds and body press tools.

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