Portfolio Daniel R. Corte 329 N. Dover LaGrange Park, IL (708) 567-8224 dnlcorte@gmail.com
Table of Contents Material Exploration
5 8
Steel Spine
Truss
digital fabrication _ fall 2010
thesis _ spring 2011-spring 2012
Conceptual Design
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LIC Cinema Competition
studio _ spring 2011
Light Bench
studio _ fall 2011
Multi-Media Library
studio _ fall 2010
Design Details & Research
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Material Strategies in Digital Fabrication
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Material Exploration Steel Spine a material case study looking at the cut and fold methods that can be placed upon sheet steel.
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Steel Spine This assignment was a product of a digital fabrication course at the University of North Carolina Charlotte. The goal for this project was to use 2’ x 4’ pieces of 16 gauge sheet steel to create a window covering. Each group received a particular production method to create this covering. The method which was chosen for this project was the cut and score. This method had its limitations as the sheet had to remain solid. This meant finding a way to fold the product into a 3 dimensional form only using cuts the cuts and dashes. Through a process of simple fold testing and tessellating a surface into triangles, we learned the materials strengths and weaknesses. This was a needed process to figure out the dashing pattern, so the final product could be assembled easily. Our final form was inspired by an equally geometric building, the Air Force Academy Chapel in Colorado Springs, Colorado. Using alternating patterns, we were able to create a simple cut and score pattern while creating an interesting surface that held variations depending on the severity of the folds in the ‘legs’ of the final form.
Inspiration
Concept Model
Pre-Construction Rendering
Team Leader: Daniel Corte Team Members: Carson Russell Ryan Martinez Joseph Coradini
Fold Testing
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Material Exploration Truss a thesis study which investigates plasma cutting and folding 22 gauge sheet steel into structural truss members. The investigation spans 3 semesters, going through various variations of ‘bi-chord’ and ‘tri-chord’ trusses. Through the experimentation, these become parametric using grasshopper that adopts the structural expression by using the loading moment diagram.
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Bi-Chord Truss The original formation of the foldable truss started as a bi-chord. This was so named because of the two adjacent enclosed triangles on the top and bottom. In between the top and bottom chords, I created a web section with triangular fold patterns to support the chords. The sizing of these are Profile and basic folding pattern created based on the loading pattern. Essentially, the larger the moment diagram at that point, the larger the triangle. This means these triangles will support more of the load being placed on the web by the upper chord, thusly transferring it down to the bottom 30 chord. In the case of the truss which was built, there is a uniform Digital mock-up of truss form load placed on the graphic.
7-3
/4”
7 - 1/16”
6 - 3/16”
Dash Cut Pattern
The45parametric piece of this truss is 0% how the moment diagram can change to whatever you may want it to. For 25% the bi-chord, this would change the 60 appearance of each truss, making them 50% aesthetically pleasing as well as adding structural stability. Uniform Load & Corresponding Cut Sheet
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The next stage of experimentation with this truss was to test its Dash Cut Pattern carrying load capacity. Through the 0% 6 - 3/16” construction of the truss, there was 3/16” 25% back and forth with paper models to fix the geometry to ensure once built full 50% 5/32” scale, there would be no mistakes. The 75% full scale mock up was then plasma cut load + Uniform Load & Corresponding Cut Sheet and folded into the correct formation. Centered Point 1/8” 30
Dash The final testing showed the Cut Pattern 3/32” usual suspect of beam failure. It 5/32” 0% experienced localized failure in the 1/8” 0% 25% 50% 75% compression chord. This occurred 25% Amount Cut after the truss was loaded with 410 3/32” pounds of weight. The impressive50% fact 0% 25% 50% 75% Amount Cut about this holding capacity is how the truss itself only weighs 7 pounds. Uniform Load + 1/3 Cantilever & Corresponding Cut Sheet 75% 3/16”
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Deflection
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/4”
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Plasma cut cutting process
Fold 1st Set
Finished, Pre-Tested Truss - Moment Curve Evident
Fold 2nd Set
Finished, Pre-Tested Truss The final form suffered from a design flaw which was not apparent in small scale testing methods. The dashes used to create the folded corners were too long in length in comparison to the amount of steel between them. This allowed for the material to deflect as seen in the image to the left. For the future iterations, this was changed to better adapt itself to the possibility of local failure such as this. By placing the dashes closer together, it minimizes the chances of this occurring. The next stages incorporated these lessons with a new profile type.
Localized Crippling
Tri-Chord Truss The new system created was formed over thorough investigation through multiple phases of testing. This method led through many different series of iterations. The original truss started as a simple equilateral shape, but through testing, was realized that it was not the most optimum profile for the distance I was spanning. A series of trials then identified the most appropriate shape. Through various other stages, the best folding angle for the plates was determined, as well as the distance of dashes to use for the folds. Once the basics of the design was determined, the folding shape was to be determined through a similar process.
Weight (oz) (oz) Weight
7-3 /4�
6 - 3/16�
60 50 40
Profile Shape to Weight held Steelgraph Shape
Through the 4 iterations of design, there were a variety of changes through the general shape of the cut patterns inside of the steel. The 1st iteration was a base 1st Iteration set that just relied on the triangulated geometries and fold patterns to keep it rigid. This pattern performed better than profile, however still failed at a point where extra reinforcement was necessary. The 2nd & 3rd iteration added those necessary reinforcements. There were extra pieces cut out of the webs to fold up and hold the top chords. Although this added strength, the truss deflected 3rd Iteration more than its predecessor, making it a poor final choice.
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2nd Iteration
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4th30Iteration
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The 4th iteration took the advantages of the 2nd and 3rd but placed those cuts in the flange of the truss. This allowed for little additional deflection while still supporting the chords, giving the truss a 30% better weight/deflection ratio than the previous tests.
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top fold over detail
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final cut sheet
grasshopper re-creation of parametric cut sheet
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close up of side with dashes & folds
profile of built truss
edge condition
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Conceptual Design LIC Cinema Competition International design competition which was focused on how we as a society should start to view a new type of movie theater. This competition also added in an ecological element; a goal to preserve or create a habitat for a species originally from the New York City area.
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LIC Cinema Competition
Site Entry & Views
The site layout we proposed was to lift all circulation and building components off the ground to allow Context for the breeding and protection of the bog turtle. The site is also modified so a natural water supply can soak certain portions of the land during high tide, a necessary part to the habitation and breeding cycles of the bog turtle. Raised exterior deck systems are placed on site for the main circulation to and from the building. Seating decks are also included for the outside movie shows which take place in the evening. The theater’s themselves have a particular orientation on the site. They are placed directly on the East Site River, focused on the views of New York. Each theater is outfitted with large vertical fins which stay open with views to the city before and after the films, and close to create a standard movie complex.
Team Members: Daniel Corte Carson Russell
View from Theaters with Slats Open
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Ma nh
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The proposal which was submitted suggested a different type of sitebuilding interaction. The normal theater digs into the site, thusly destroying the landscape and ridding the site of any previous inhabitants.
ive r
This assignment was a product of a topical studio which focused on a variety of constraints. This instance was the habitation of bog turtles.
exterior rendering as viewed from the entry decks The theaters were broken up into tower units which held 3 theaters, the structure for those theaters, as well as the movement bars. This unit was replicated at the respected viewing angles. Each theater in these units are a different size to host different movies with different crowd sizes, according to the program.
theaters
movement
theater unit
structure
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Conceptual Design University of Wisconsin Media Hub A comprehensive studio project which lead student designers to create a media hub and library for students and faculty on an alternative university campus.
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Multi-Media Library The multi-media library designed here is for the University of Wisconsin - Madison. This particular building is to serve as a compliment to the large library system already in place. This outpost is to serve the sciences which are stationed directly west. It is also at the intersection of a few different parts of the campus. This building can connect the natural landscape to the north with the neighboring athletic fields, research park, as well as the rest of campus to the east. This position makes it a landmark to the landscape. The parti of the building comes from the movement on the site. It takes the people coming from all the different sections of the university and funnels them into the space. This allows for the building to be partitioned into three different zones with a common area. This library is host to a variety of different functions. It hosts four stories of book stacks, a wing dedicated to office and meeting spaces, as well as a spot for classrooms. There is also one section devoted to digital and monologue presentations, located on the overhang portion of the building.
Site Plan + Movement
Concept Evolution
Book Stacks / Offices / Classrooms
The folding nature of the building form creates building shading devices which cover the library stacks from the degenerative nature of the sun. It also folds around to create walk out spaces for patrons to use them during the summer months.
Concept Structure Model
1st Floor Plan
Exterior Sun Control Device Flexible Flashing 2” x 4” Tube Steel
Aluminum Windows Composite Panels Gypsum Board Non-Load Bearing Wall Framing
Flexible Flashing Anchor Bolt Soil Sheet Waterproofing 4” Insulation Structural Concrete #4 Rebar Wall Section and Call Outs
Concept Rendering
2nd Floor Plan
3rd Floor Plan
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Conceptual Design Light Bench A project which experimented with moving light through a space using parabolic curves and removing glare inside of a building.
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Light Bench The light bench is a group product of a topical design studio in fall of 2011. This studio focused on transforming spaces through unusual means. The presentation space adjacent to the Storrs Library contains a western facing facade with a fully glazed wall. The space is very inefficient, especially during its peak occupation hours (2pm-6pm). The sun’s altitude causes increased levels of solar radiation and an overabundance of light. The space feels uncomfortable and the quality of light is not conducive for visual presentations. Our goal for this space is to decrease solar heat gain, provide even light distribution, and lessen the glare in the space. To do this, we started to look at precedents of reflecting solar rays, thusly decreasing glare and giving the space a more even light. It was noted that depending on a curve of a reflected surface, you can focus light to a specific point in space. This idea would allow us to redirect the light with mirrors deep into the space. This left us with the want to decrease solar heat gain near the windows, which created a heat island which was uncomfortable to be in. This is done by the design and integration of a moving shade and bench component. The shade moves in accordance to the angle of the sun, and never allows for direct light to enter the space. The bench blocks the light too low to diffuse, allows for students to utilize the space against the windows comfortably, and protects the louvers which are behind it. Team Members: Daniel Corte Ryan Barkes Wynn Buzzell
2pm 2PM RAY TRACING
4pm 4PM RAY TRACING
6pm 6PM RAY TRACING
Solar Ray Tracing Using Parabolic Curves Using Grasshopper we devised a code that traces solar rays and adjusted louver angles simultaneously. This helped us optimize the mirror angles to fractions of a degree.
Shade Component
Exploded 3D View of Bench
Materials: -Mirrored louvers -Layered 3/4� plywood bench -Wooden buttresses -Fabric shade -Steel connections -Arduino sensors & motors
Fixed Louvers Servo Gears
Fabric Shade
Moving Louvers ?Control Arms
Fixed Wire Connection Circuit Board Servo
Moving Components
Mirror Components
Exploded 3D view of connection
Rendering of fully installed pieces
Units aligned
Single Bench Unit
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Design Details & Research This section is dedicated to smaller scale projects. This includes work done in the digital arts center for project research and investigation due to material constraints in digital fabrication.
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290 Mulberry Research conducted on the 290 Mulberry project by SHoP Architects in NYC was based on their custom form work and the constraints to the size of a standard brick. The shape which was created served SHoP as a panelized unit which bricks could be laid into the CNC’ed spaces. The process to do this had them create a piece of simple form work which had points that were pushed and pulled. This created a base geometry that the panel would then sit on. As shown in the diagrams, bricks would then be placed in the appropriate slots. The panel would then have a concrete mixture poured on top of the bricks to make the panel structurally stable. Once cured, the panel could be lifted out of the form worm, and transported on site. The form work would be left in tact to allow for additional panels to be made.
push and pull points
brick grid applied to surface
CNC out brick negatives
close up of CNC form work
inlay bricks
concrete over pour
final product
Biomimetic Responsive Surface Research done by Achim Menges, the biomimetic responsive surface incorporates dimensional changes which are triggered by changing climatic conditions. To break that down, the system at hand is allowed to be applied to any surface. This was tested with this project at hand. The idea behind the dimensional changes by a climatic conditions stems from the idea of a pinecone. Under the correct humidity, the shell opens itself to release the seeds. Menges uses a similar wood to adapt the surface in the same way. This provides a conceptual climatic response system which has the ability to conform to any surface. The advantage of this system is that there is no need for an outside power source , making the material elements key. This idea is looked to expand itself into other circumstances other than the simplistic open/closed condition.
surface created through section
rebuild to create squares
extrude linearly in the z-axis
focus in on 3x3 section
move units down incrementally
triangulate curved surfaces
final product with flaps closed
final product with flaps open
1" Immaterial - 4Ultramaterial 21'-10
1" 12'-22
Research for project was conducted by Harvard University’s Graduate School of Design that investigated new materials and novel applications of known materials. This project is in a set of projects that explore different types of fabrication. The hope is that the evolution of a process and the concept of form would continue the evolution of architecture. For this particular process, Wood paneling was laser cut into rectilinear like forms with different cut and score marks in the center face. This allowed for the material to move in unconventional ways. The relationships between material and design in this project shows that flexibility of the material while creating form has an extreme effect on its final form and the way it reacts to different loading types.
sectional line work
3D surface created
call out of connection pieces
close up of small material
cut and insert method
connection detail
final rendered product
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