Dan Rothbart - DIGITAL / MATERIAL - Portfolio Fall '21

DIGITAL / MATERIAL

by Dan Rothbart Master of Science in Design: Robotics and Autonomous Systems - University of Pennsylvania, 2021 Bachelor of Architecture - Rensselaer Polytechnic Institute, 2020 Supporting video content at danrothbart.cargo.site

Contact information: dbrothbart@gmail.com

Table of Contents Academic University of Pennsylvania

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Industrializing the Bespoke 3-person team, half-semester studio

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Fairmount Hydro - farm 3-person team, half-semester studio

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rotobodies (W.I.P.) Full-semester studio: integrated across courses

Rensselaer Polytechnic Institute

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CO-PORT Schematic Design: individual studio Design Development: partner studio

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Cycle-of-Parts 3-person team studio

Materials and Enclosures Group technical seminar

Active Rock Individual studio

Habitat Nexus Partner studio

Professional Archi-Tectonics NYC, LLC

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WORK | INFO | NEWS

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Asian Games 2022 Masterplan and Stadiums

Website Management Archi-Tectonics Team

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Tel Aviv University School of Architecture Archi-Tectonics Team

Weitzman School of Design, University of Pennsylvania Master of Science in Design: Robotics and Autonomous Systems - Class of ‘22 Robotics Lab Operator - Spring ‘21 RAS Representative and Admissions Ambassador - Fall, Spring ‘21

INDUSTRIALIZING THE BESPOKE 8-week studio project (partners: Layton Gwinn, Sophia O’Neill critic: Andrew Saunders), 2021 As the first studio project in the MSD-RAS at UPenn, this project rapidly introduces the students to a workflow in which machine learning, parametric analysis, robot programming & operation, and robotic fabrication serve as design inputs in the proposal of a drop ceiling for one of the gallery spaces in the building.

Students parametrically recreate sculptures from constructivist brothers Naum Gabo and Antoine Pevsner, and create an abstracted study model from them: ours shifted the sculpture’s airy openness for a more captured feel. This study model was rendered and collaged to form half of the input for a convolutional neural network written by the faculty, the other half being a “canvas” on which to redistribute “features” from the rendered imagery.

Using the IRB 4600 and its custom hot-wire-cutter end effector, ruled surfaces with custom tooling relief patterns are carved out of blocks of EPS foam. A portion of the proposed ceiling was fabricated at a scale of 6” to 1’-0” and mounted in the space.

Role: paremetric & 3D design, robot programming & operation, fabrication & assembly, architectural drawings & diagrams, video production & editing.

Installed 6” to 1’-0” prototype: a portion of the proposed ceiling in EPS foam. Designed, robotically fabricated, assembled, and installed by the applicant and partners. Approx dimensions: 3’ x 3’ x 1’.

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From top left to bottom center: Antoine Pevsner’s Developable Column 1942 and parametric recreation, abstracted study model * rendered by applicant partner, generative collage input, soviet mosaic wall tiling retrieved from Google Images, CNN style transfer iterations100-700, and selected output for 3D design study.

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Above: reflected ceiling plan of proposed ceiling | Below: longitudinal section of the same. * rendered by applicant’s group partners.

Left: program and simulation of robotic movement, toolpath exeution, half-fabricated artifact, and worms-eye perspective of the proposed ceiling. | Right: final fabricated prototype

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FAIRMOUNT HYDRO - FARM 8-week studio project (partners: Layton Gwinn, Sophia O’Neill critic: Ezio Blasetti), 2021 As just a half-semester studio, this project engaged the computational design, structural analysis, embedded micro-controllers, robot programming, and robotic fabrication of carbon-fiber components in an urban intervention, explored through the installation of a 1:1 fabricated prototype. A custom winding pattern enabled components to form the lines and nodes of their structure, and an embedded hardware detail enabled connection between components.

The lightweight intervention sited itself adjacent to The Fairmount Water Works, which was built to provide the city of Philadelphia clean water by 1815, the first of its kind in the United States. The project sees the Water Works and the surrounding Fairmount Park as a hybrid condition between natural and man-made; a synthetic garden at an urban scale. Recognizing today’s advanced information technological era, a similar synthetic was deployed: sensing and pumping systems inform a hydroponic urban farm within the carbon fiber infrastructure.

Role: robot programming and operation, detail design, fabrication, and assembly of 1:1 prototypes, topological structural analysis, architectural drawings and diagrams, drone scanning and 3D modeling of existing condition via point cloud.

Historical drawing of Fairmount Water Works c 1815, adjacent to original rendering of proposed infrastructure, in present day site, verified by photogrammetry point cloud produced by applicant

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Composite Computational Form | Stuart Weitzman School of Design, instructor: Ezio Blasetti

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design team: Layton Gwinn, Sophia O’Neill, Dan Rothbart

Left: one of 4 modules of the 1:1 prototype, roughly 2’ x 2’ x 2’ in size | Above: step-by-step representation of robotic weaving pattern for spatial knot condition | Below: IRB-120 and carbon-fiber end-effector winding around threaded rods, spatial knot and embedded hardware, and detail connection between components

Compression vs tension analysis

Load case

Compression Tension

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2a Step 2 Carbon fiber structure

Step 4 High deflection Low deflection

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Supports Voids Hydroponic planters

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Left and Center: exploded axonometric representing (1) topological structural analysis via Millipede, and (2) (a) structural analysis via Karamba (b) recursive tetrahedral subdivision algorithm: larger scale components align with tensile zones and smaller with compressive. (c) algorithm to determine feeding system for hydroponics, written by applicant and instructor.

Left: renderings in point cloud of site | Right: images of fabricated prototype, using a different aggregation logic than the digital design, but an analogous, and functional, hydroponics system controlled on-demand. Seedlings of basil in growing medium pictured here, housed in 3D printed planter and machined PVC pipe, by applicant.

Real-time program

‘Robot’ manipulation

Ghpython: contrast, kclustering, polyline

Computer-vision ‘scan’

User draws line, intigating & responding to robot Real-time interactive drawing: utilizing Ghpython, MachinaBridge, RobotStudio, Firefly for C.V.

Clay 3D printing extrusion: cellular automata computational logic drives toolpath difference

Manipulation of matter: cellular automata in time steps creates robot toolpath, material effect

Automated pick and blocks, GhPython scri

place: given any input of ipt creates stacking output

rotobodies (W.I.P.) Integrated studio project (partners: Davis Dunaway, Layton Gwinn critic: Robert Stuart-Smith), 2022 The seminal project in the MSD-RAS is integrated across four courses in the Spring semester. A 15-week design research project, rotobodies will represent the creation of a novel fabrication process for the production of bespoke architectural ceramic components, sited on a prototypical storefront facade. Beginning with a modified literature review on architectural ceramics and a series of technical workshops (pictured left), the work is currently being supported by coursework in real-time robot programming and XR development, as well as an industry-standard end-effector design course, thus developing digital and material tooling custom to our project and its fabrication process.

Pictured here from left to right: real-time interactive drawing with the robot, pre-programmed clay extrusion with material effects driven by computational design, displacement of wet clay based on the same logic of distribution, and automated pick-and-place. The first, third, and fourth project required the design and fabrication of custom end-effectors, with the first embedding a Logitec webcam and accepting different drawing utensils.

Left: Visualizations of potential aggregations of malleable slip-cast components | Right: hand-rotated slip-cast forms. Roughly 5”x5”x5” and 8”x8”x8”, respectively

rotobodies seeks to leverage robotic motion in an automated slip-casting fabrication process capable of bespoke results despite using the same mold. The project will be delivered May, 2022 and include ...

- literature review: architectural ceramic assemblies & ecology. Peer-reviewed sources - development of custom real-time robot collaboration in AR / VR: Unity, MachinaBridge, HTC Vive - fabrication of custom end-effector tool for robot: Fusion 360, Computer-vision, MachinaBridge - computational approach to facade design: Rhino, Grasshopper, GhPython, Maya - robotic slip-casting capable of bespoke results: Visose Robots, RobotStudio, MachinaBridge - firing, glazing, assembly of 1:1 fabricated prototype, including architectural detailing - analysis of the different results produced: thermal imaging, translucency, shrinkage - research paper for submission to ACADIA - project thesis book

School of Architecture - Rensselaer Polytechnic Institute Bachelor of Architecture - Class of 2021 Course Assistant Design Studio 2, Design Studio 6 - 2020 Several works archived for publication on Dezeen, Influx Vol. 2

CO-PORT Co- pref.

1) Together; joint; jointly; mutually: coeducation 2) a. Partner or associate in an activity: coauthor b. Subordinate or assistant: copilot 3) To the same extent or degree : cotangent

Port n.

1) a. place on a waterway with facilities for loading and unloading ships b. a city or town on a waterway with such facilities c. the waterfront district of a city 2) A place along a coast that gives ships and boats protection from storms and rough waters; a harbor.

3) A port of entry

CO-PORT Semester 1: Schematic Design (individual, critic: Javier Giorgis) 2019, Sem. 2: Design Development (partner: Felix Reyes, critic: Florencia Vetcher) 2020 Finding its form as a directive for the City of Troy to face its identity as a post-industrial waterfront with civic potential, the 50,000 sq ft CO-PORT bridges over a new transportation hub with a ‘folding’ public passage walkway, connecting the city to a new riverwalk among a public library, co-working hub, auditorium, and cafe.

Piercing through this double enclosure to the South, a 120-seat auditorium introduces an abrupt vector of heightened spatial experience, cantilevering over the co-working commons and cafe, augmenting its auditorium space, and engaging the public plaza toward the water.

This project was initiated by myself during a semester-long individual Design Schematic studio, and was selected by SoA faculty to continue through Design Development in a subsequent semester-long partner studio.

Role: site, context, and concept research, 2D and 3D design, physical models (individual studio), program and occupancy code compliance, 2D, 3D, parametric, and construction detail design, renderings, physical models (partner studio).

Original rendering of Design Development project in context, with the city on the right, and the water on the left. Produced by applicant

CITY

RIVER PUSH IN TO INVITE CITY

PUSH IN TO FACE RIVER

CUT + HOLLOW FOR TRANSPORTATION HUB CUT + HOLLOW FOR PEDESTRIAN ACCESS

Left: Schematic Design massing | Above: Image-responsive parametric facade Bottom: applicant and partner-produced rendering of plaza entry from city

Original cross section and construction details of the same. Produced between Revit, Rhino, Illustrator, and Photoshop (Design Development phase) Following spread: comprehensive visualization of user experience, produced by applicant and partner (Design Development)

Cycle-of-Parts Design Studio 7(partners: Catriona Cribb, Catherine Gaspard, critics: Daniel Rosenberg, Director Dennis Shelden) 2020 Addressing the challenges of construction-industry landfill waste, affordable housing, construction-industry workforce, and a few of COVID-19’s several reverberating effects, Cycle-of-Parts provides labor training opportunities in the demounting of condemned buildings and waste & material reuse, forming flexible kit-of-parts-based modular building components, engaging city after city via an urban acupuncture strategy, transforming vacancy into an asset.

Aggregate material and 2-by construction are reused, in the production of novel gabion facade and foundation blocks and hybrid new-wood-reused-wood-newwood Cross Laminated Timber panels. 3 key modules are developed, which can aggregate to form an affordable housing massing to fit several site dimensions, public services for the community, and its own manufacturing / mixed use space.

In the first location, when the factory infrastructure moves to the next town or city, the space is repurposed as a community center, here housing tutoring, day-care, and more to address effects of the COVID-19 pandemic.

Role: 2D, 3D, and parametric design, site, concept, and statistical research, material flow, construction sequence, and manufacturing process research and design.

Completed in a group of 3 students.

Original rendering of completed massing, with housing and mixed-use above manufacturing facility

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Demount existing structure, collect materials

2 Screenshot of Rhino Grasshopper parametric script developed by applicant and group

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Construct factory from reused and new wood

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Construct housing bloc above

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4 Diagram produced by applicant of parametric approach to modular housing throughout the city

Engage broader area via row site housing Left: original rendering by applicant of first manufacturing facility, in Troy, NY | Above: site strategy timeline for the initiative’s first lot in Troy, NY, * drawn by group member

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‘Rooms as modules’ housing organization

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Condemned structures

Sustainably-sourced dimensional lumber

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Enclosed organization of Troy, NY factory building

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(From center image) (From center-right image) D- spandrel panel A- full module B- post and beam construction system E - gabion facade panel F - premanufactured window C- insulated aluminum panel G - exterior cladding panel H - insulation

(From center image) I - interior cladding panel J - full interior partition panel K - perforated panel M - adjoining frame connector N - 4-way steel tube connector

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Enclosed organization of Troy, NY row site buildings

Left: material flow diagram * | Right: original rendering of community center educational program, after manufacturing facility is moved to next location

Materials and Enclosures Group technical seminar (Partners Felix Reyes, Tyler Babb, Sam Harrison critic: Gaby Brainard) 2019 An exploration into Fiber-Reinforced Polymer as a facade material, patterns of tessellation, and the hook-on-cassette joint. The system my group and I proposed solved itself within each individual unit: with the FRP cast integral to backup rods followed by fire and waterproofing, each unit can have over 3 inches of insulation sandwiched between vapor barriers. Each unit then hooks into an aluminum frame, which is drilled into the concrete backup wall.

An over-arching pattern is achieved with just 1 panel variation, and over the course of the day, this undulating surface displays a range of light and shadow, resulting in a dynamic continuous-yet-panelized wall system. A laser-cut, hand-cut, and vacuum-press physical model was produced by the group, as well.

Role: material and construction system research (group), 3D and physical models (group), plan, detail plan, and detail section drawings (individual).

Photograph of completed physical model, with one operable panel removed. Model produced by applicant and group

Aluminum Frame R-value = 0.61 Thickness = 1.5”

Concrete wall R-value = 1.60 Thickness = 8”

Vapor Barrier FRP Panel R-value = 0.47 Thickness = 0.188”

R-value = 0.00 Thickness = .25”

Insulation R-value = 18.00 Thickness = 3.8”

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Backup wall Structural sealant Connecting bolts Vapor barrier Rigid insulation Fireproof membrane Waterproof membrane Hook-on-cassette rails Backer rod cast into FRP panel FRP panel

Left: Thermal and vapor management system * drawn by group member | Above: solid foam was CNC-milled and vacuum-formed around by applicant for prototype mockup Right: elevation, plan, and detail plan drawings by applicant

featured in

Habitat Nexus Design Studio 4 (partner: Andrew Tice, critic: Yael Erel) 2018 Featured in Dezeen’s “10 futuristic architecture projects from Rensselaer Polytechnic Institute students” online article, Habitat Nexus was selected by Dean Evan Douglis to represent the curriculum’s AD4 - Housing studio in this publication, and in RPI School of Architecture’s upcoming Influx 2.0 comprehensive monograph.

Habitat Nexus forms its architecture as a vessel through which to break the fabricated reality of connection and community promised by technology and social media through extreme architectural environments fomenting physical intersection and interaction of the bloc’s inhabitants.

Role: 2D and 3D design and drawings, parametric analysis, site and concept research, physical models, renderings, etc. (partner studio)

Original “Statement” image of the project’s responsivity to its context, by applicant

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Left: waterfront landscape perspective | Right, from top left to bottom right: initial spatial folded models*, unit bedroom light diagram*, rooftop landscape perspective, site plan, courtyard perspective, interior unit perspective. All perspective images were rendered by applicant and entouraged by applicant’s partner. Site plan by applicant.

WORK | INFO | NEWS Website management 2018-present: archi-tectonics.com Principal: Winka Dubbeldam - wd@archi-tectonics.com The rest of the work displayed in this portfolio was done by the applicant in a professional capacity for ArchiTectonics, NYC. I joined this office just after the competition victory described by the next project. I have worked in a continual basis uploading all of the text, photo, and video present on Archi-Tectonics’ new website individually, through a back-end coded by WSDIA, while working as a Junior Designer on the projects described after this one.

Role: uploading and managing all of the text, photo, and video present on Archi-Tectonics’ updated website, aiming to display the firm’s larger projects, as well as showcasing the beauty and design intelligence of all works. This often involves writing copy for and linking between social media posts, Vimeo, Netflix, etc., as well as some HTML coding.

www.archi-tectonics.com landing page, photograph by Eric van den Brulle

From top left to bottom right: archi-tectonics.com/work (which links to image below: 512 GW Townhouse), archi-tectonics.com/info (which scrolls to image below), architectonics.com/news (which scrolls to image below: Inscape Meditation Center featured in Netflix’s The Mind, Explained

Visitors & Exhibition Center, distributed park facilities (194,000 sq ft) Field Hockey Stadium (172,000 sq ft)

Table Tennis Stadium (365,000 sq ft) Fitness Center (250,000 sq ft)

Yuying Road Beizhuang River Valley Village shopping concourse (387,000 sq ft)

Underground parking (732,000 sq ft)

Asian Games 2022 Masterplan and Stadiums 2018 - present | Studio: Archi-Tectonics Principal in Charge: Winka Dubbeldam - wd@archi-tectonics.com 116 acre Eco-Park designed with !melk & 7 buildings (1,800,000 sq ft gross) designed with Thornton Tomasetti. Competition victory 2018, construction phase 2019-2021, opening by 2022 Asian Games, Hangzhou, China.

The masterplan is organized along a Body within Body concept, with a stadium anchoring each end of the site, connected by an undulating indoor-outdoor shopping concourse, all integrated within a zero-earth landscaping strategy.

Role: 3D, parametric, and physical models, original drawings, diagrams and renders, strategic 2D edits to outsourced renders, award submission and social media campaign for Architizer A+Popular Choice Awards victory.

Some of the following images are created originally by the applicant, for an upcoming book to be published by Archi-Tectonics in May 2021, noted at the bottom of the spread as ‘original’. Others are strategic 2D and 3D montage edits to outsourced images, communicating updated design decisions of Archi-Tectonics’ to collaborative firms worldwide.

Original drawing and rendering by applicant: the masterplan’s main compositional elements

Left: outsourced image *, applicant 2D montaged brass facade, 3D montage of stadium interior, and 2D montage of tree entourage to the right | Right: Original drawing and render of Table Tennis Stadium’s essential elements, produced individually by applicant

5.5m x 2.5m Double-glazed planes Triangulated aluminum T-profile supports Steel diagrid primary structure Steel cable secondary structure

GFRC and interior finish Steel superstructure Fiberglass batt insulation Exterior metal stud framing TECU overlapping brass shingles

Left: original drawings and renders of Stadium’s facade systems, produced individually by applicant | Right: construction progress, January, 2022

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Tel Aviv University School of Architecture Competition Honorable Mention 2019. Studio: Archi-Tectonics Responding to a unique brief; a new 62,500 sq ft gateway building including a school of architecture, a commercial mall, cinemas, private archives, and future flex space, Our design concept proposes a hybrid structure for new campus identity: a didactic, active agent in the city, embodying a higher social / cultural / environmental awareness for the campus.

During the initial research, I identified “gateway”, “natural ingredients”, “identity”, “innovation and technology”, “flexibility”, and “collaboration” as drivers for this 3-dimensionally complex building.

Role: individual design and concept research (solo), competition submission (team), 3D and parametric design (solo)(auditorium, parametric ellipsoid stairs, building superstructure, rendered in black in the following images).

Original climate diagram and rendering produced individually by applicant

Left: Original drawing of ellipsoid stair, drawn and designed by applicant using script by Paul Wintour | Right: Archi-Tectonics’ * rendering of the same

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Left: Archi-Tectonics’ * school of architecture rendering, within 3D model managed by applicant | Right: auditorium, designed and drawn by applicant

Thank you Dan Rothbart dbrothbart@gmail.com danrothbart.cargo.site