WireVoxels | Presentation

WireVoxels

DON GH WI K I M T h e Bar t le t t S c hool of Arc hit e c t ur e Marc h Arc hit e c t ural De sig n R e se arc h C lust e r 4

INTRODUCTION Research Strand

Hand Craft

Mass production

Digital Turn

60s

Digital Turn

90s

Digital Mass Produc-

PIXEL TO VOXEL

Pixels

Combinatorics Voxel

Data

Combination of Voxels

VOXEL Continuity; Combinatorics; Density; Printability

Continuity

Density

Combinatorics

Printability

COMBINATION OF VOXELS

Materiality

plaster

plastic

silicone

wax

acrylic

ABS filament

INITIAL DESIGN Voxelised Chair

Reference Chair

Stress analysis

Voxelization

Fabricated Chair

INITIAL DESIGN Voxelised Chair

INITIAL DESIGN Curve developments

Solid

Container

Curves in Container

INITIAL DESIGN Curve developments

ABS filament

Graphic theory

Iteration 1

Iteration 2

Iteration 3

Printability

INITIAL DESIGN Test case : Chair No.2

Low density chair

Medium de

ensity chair

High density chair

MATERIALITY Limitation of plastic extrusion

3D Printed Architecture In r ec e n t ye ars , 3D rapi d protot ype m ac h i n e s have be c om e m ai n s t ream . Par t i c u l arl y, 3D Pr int e rs h ave be e n i n t h e s pot l i g h t , n ot on l y f or bus i n e s s u s e s bu t al s o f or i n di vi du al h ob bies a n d D.I .Y at h om e . H ow eve r, 3D pri n t e rs t hat us e pl as t i c e x t ru s i on e x pos e a n u m be r of limit a t i on s . T h i s i s du e to t h e m ac h i n e on l y be ing ab l e to m ak e l aye rs of t h i n l i n e s , an d du ri n g t he proc e s s , w h e n i t m ak e s a l i n e i n m i dai r, t h i s condi t i on i s n ot s u i t abl e f or m ak i n g a s t rai g h t line. Th e pl as t i c m at e ri al of t h e 3D pri n t e r i s too weak to m ak e a s i n g l e l i n e i n t h e ai r. M ore ove r, in r eal i t y, s i n c e i t t ak e s t i m e f or t h e l i n e to s o lidif y an d du e to t h e g ravi t y, t h e e x t ru de d s i n g l e line c an n ot be a s t rai g h t l i n e . I t c an be be n t an d broke n e as i l y. I n addi t i on , t h e m ac h i n e s re qu i re suppo r t i n g bas e w h e n pri n t i n g t h e obj ec t w h i c h could l e ad to w as t i n g a l arg e am ou n t of m at e rial, wh i l s t on top of t h at , s l ow i n g dow n t h e pro -

Limitation of Plastic Exturding

When we con s i de r t h e s e probl e m s at h an d, w e search f or a be t t e r opt i on an d i f w e c an m ak e a st rong sing l e l i n e i n s pac e rat h e r t h an vol umes, we can al s o i m ag i n e a n e w k i n d of pri n t ing met hod w h i c h c an c om pe n s at e t h e de f e c t s of 3D pr int e rs . As a re s u l t , w h e n w e u s e m e t al wir es, we ca n s ol ve t h e probl e m s s i m pl y. T h i s is because t h e m e t al w i re s are s t ron g e n ou g h to make a s i n g l e t h i n l i n e i n a s pac e . M ore ove r, t hanks to advan c e d robot i c t e c h n ol og i e s or programs, w e are abl e to c al c u l at e eve ry be n d point s of t he m e t al w i re s to m ak e a s pe c i f i c g eomet r y to m at c h w h at de s i g n e r w an t s , an d t h i s allows t he c re at i on of i n t e re s t i n g c om pon e n t s , voxels or modu l e s ve ry rapi dl y an d pre c i s e l y.

Fur t her mor e , w h en i t c om e s to t h e Arc h i t e c t u ral indust r y, t his c an g i ve a s e n s at i on al i m pac t on , not only t he c on s t ru c t i on f i e l d bu t al s o de s i g n met hodolog i e s w h i c h are bas e d on t h e m odu l ar syst em.Due to t h e proj ec t ai m i n g to de al w i t h lines mor e t h an m as s e s , re du c i n g w e i g h t an d volume of g e om e t ry by t ryi n g to c re at e a c on t inuous line i n s i de a u n i t ( vox el ) w as f oc u s e d on, avoiding e i t h e r f abri c at i n g or c as t i n g h e avy mat er ials. N ot on l y t h i s ai m , bu t t h e proj e c t also envision e d i de as to t h e n e x t s t e p i n c re at ing met al wire be n di n g t h at c ou l d g i ve t h e project mor e ben e f i t s c om pare to c as t i n g or pl as t i c ext r uding w h i c h m ay h ave s om e e rrors , prob lems of st r u c t u ral re i n f orc e m e n t i n l arg e r s c al e and cannot be re u s ed an d re c yc l e d.

Ther ef or e, th i s re s earc h ai m s to e x pl ore t h e jour ney of fabri c at i on f rom c on t i n u ou s to di s cr et e and how e f f i c i e n t i t c an be i f w e u s e ro bot s not onl y i n t h e f abri c at i on bu t al s o i n t h e assembling proc e s s c om pare d w i t h m an u al as sembling as w e l l as to s e arc h h ow to appl y to t he archit ec t u ral de s i g n .

Wire Frame Architecture

MATERIALITY Bending factors Understanding Springback Thickness

Actual Radius

Bending Angle Bent Angle

Bending Radius

The two reasons of Springback l. displacement of molecules within the material ll. stress and strain.

Tensile Stresses

Compressive Stresses

0

Neutral Axis

As the material is bent, the inner region of the bend is compressed while the outer region is stretched, so the molecular density is greater on the inside of the bend than on the outer surface.

The compressive forces are less than the tensile forces on the outside of the bend, and this causes the material to try to return to its flat position

Factors that control or influence the success of a bending operation - Thickness The thicker the material, the less the springback.

- Tolerance When metal is thicker or thinner, it is squeezed less or more in the bending operation, respectively.

- Size The size of the inside bend radius also affects the amount of springback. The larger the bend radius, the more the springback.

- Speed The speed at which the bending takes place also affects springback. Generally, faster forming speeds reduce the amount of springback.

- Grain direction The grain direction is established during the metal rolling process. Bending with the grain gives a different result than bending against it.

- Friction During bending, the metal is forced between the lower die section and the forming punch. If the clearance between these two sections is less than the metal thickness (as it usually is), intense friction is created.

FABRICATION STRATEGY Bending machine

Industrial Bending Machine

About the bending part of this machine is ideal for difficult job situations and fatigue, thanks to its one-block body and excellent mechanical characteristics. The bending disk can be rotated in two ways - clockwise and anti-clockwise. It comes with all the essential characteristics needed for normal bendings.

The excellent design of the machine and the modern technology embedded in it promises optimal performance while utilizing low power. Here are some of the accessories used with this machine - tool set for stirrup bending speed variator, double foot pedal, selector panel and special tooling for spirals.

Z AXIS ROTATING WIRE HOLDER EXTRUDER WHEEL BENDER WIRE HOLDER BEARING BEARING

MOVEMENT

STEPPER MOTOR

STEEL ROD

SOLENOID BENDER WHEEL

STEPPER MOTOR

SUPPORT SUPPORT

STEEL ROD

DRIVER

ARDUINO BOARD

BREAD BOARD STEPPER MOTOR 23

FABRICATION STRATEGY Bending machine

INITIAL DESIGN Test case : Chair No. 3

TOP

FRONT

BACK

SIDE

OVERLAPPING STRATEGY Test case : Chair No. 4

Chair voxelisation & Stress Analysis

Low Stress

Original line

High Stress

Double lines

Highest Stress

Triple lines

INITIAL DESIGN Test case : Chair No. 4

INITIAL DESIGN Test case : Column no.1

INITIAL DESIGN Test case : Column no.1

INITIAL DESIGN Test case : Column no.1

Geodesic Dome at EXPO ’67 In f ac t , t h e m e t al w i re w ork i s n ot n e w t h i n g i n t h e arch i t e c t u ral f i e l d. I n t h e 20t h c en t u ry, m an y m e t al wire buildings had not only demonstrated beauty but al s o t h e s u c c e s s f u l prof i t of t h e m et al w i re , e x a m p l e d b y a m a z i n g a rc h i t e c t s w h o p u r s u e d ‘ H i g h t e c h A r c h i t e c t u r e’ . M a n y p e o p l e h a v e s u p p o r t e d t h e m e t a l w i r e s t y l e i n a rc h i t e c t u r e f i e l d s b e c a u s e of its be au t i f u l of appe aran c e bu t al s o i t s pros pe r ous economics for the construction and maintenanc e .

A spac e f ram e by B u c k m i n s t e r f u l l e r, an e xc e l l en t pione e r, i s e c on om i c al l y f e as i bl e an d h as a h i g h durabil i t y an d produ c t i vi t y. How eve r, i t h as t e n de d to show h ow h om og e n e ou s t h e pat t e rn an d s h ape as desi g n ou t pu t s c an be , w h i c h m ay n ot be t h e M od er nis t s ’ on e. T h e bu i l di n g s by Zah a Hadi d, t h at s h ow anot h e r l eve l of t h e u s e of s pac e f ram e s h ow h e t eroge n e ou s s h ape s . N eve r t h e l e s s , s i n c e t h e eve ry beam i s di f f e re n t , i t t ak e s a l on g e r am ou n t of t i m e and e x pe n di t u re i n f abri c at i on an d as s e m bl i n g . Fu r t her m ore , t h e proj e c t ‘ C l ou d of V e n i c e’ w h e re t h e most advan c e d t e c h n i qu e s w as appl i e d i n t e rm s of wir e f abri c at i on , at t e m pt e d eve ry c om pon en t s to unit iz at i on . How eve r, i t di d n ot ove rc om e t h e re pe t it ive, h om og e n e ou s s h ape l i k e B u c k m i n s t e r f u l l e r ’s one. T h i s i m ag e c om pare s an d s h ow t h e l i m i t at i on of t he re c e n t s pac e f ram e s t ru c t u re .

Thus , t h i s re s e arc h ai m s i n ac h i evi n g t h e m e t h od to make i t pos s i bl e i n bu i l di n g a h e t erog e n e ou s f orm st r uc t u re as Zah a Hadi d h as i n h e r arc h i t ec t u re whils t f abri c at i n g m e t al w i re e f f i c i e n t l y l i k e B u c k mins t e r f u l l e r at t h e s am e t i m e . T h i s i s t h e re as on why t h i s re s e arc h u s e s t h e m e t al w i re s an d c om bi natori al vox e l s .

Roof Construction for Aircraft Hangar, Konrad Wachsmann, 1951-1953

Heydar Aliyev Center, Zaha Hadid, 2007

Clouds of Venice, Supermanoeuver, 2015

MATERIAL RESEARCH

Aluminium

Bronze

Copper Coated Mild Steel

Gavanised Steel

Expensive

Very expensive

Cheap

Very cheap

Excellent

Good

Good

Fair

Poor

Fair

Good

Fair

Poor

Fair

Good

Good

Light

Heavy

Heavy

Heavy

Mild Steel

Very cheap

Stainless Steel

Very expensive

Good

Good

Good

Excellent

Titanum

Zinc

Very expensive

Very expensive

Fair

Fair

Excellent

Fair

Good

Good

Good

Good

Heavy

Heavy

Light

Light

FABRICATION DEVELOPMENT Customised Robotic bending

Rotating bender

Gripper holder

Bending tools

Feeding part

Bending part

FABRICATION DEVELOPMENT Customised Robotic bending

Feeding gripper

Bending table & Bending gripper

Mounting Plate

Ball Bearing 698Z Roller Shaft

Hex Head M3 Bolt (15mm) Collar Roller Shaft Ball Bearing 698Z

Hex Head M3 Bolt (15mm) Table

Hex Head M3 Bolt (30mm)

Table

FABRICATION DEVELOPMENT Bending Voxels

Type 1B x 2 Type 1A Type 1C x 2

Type 1D x 2

Line type 2 Line type 1

pe 1A

Ty

x2 e 1B Typ 1C e p Ty

Voxel type 01

-m e 1C Typ 2 Dx 1 e Typ

Voxel typ

Type 2D

Type 2G

Type 2C

Type 2H

Type 2B x 3

Type 2F x 4

Type 2J

Type 2A x 3

Type 2E x 2

Line type 2 e 2E

Typ e 2A

Typ

x2

x3

x4 e 2F

e 2B

Typ

pe 02

x3

e 2C

Typ

x1

e 2D

Typ

Typ

x1

e 2G

Typ

e 2H

Typ

e 2J

Typ

Voxel type 03

DESIGN DEVELOPMENT Test case : Chair no.5

160 mm

28 Voxels

Stress analysis

Voxelisation

ALIGNMENT

BRACING

OVERLAPPING

ELONGATION

A0

B0

A0

B1 A1

A3

B4

A5 B1

A2 A3

A4 A3

B0 B1 A6

DESIGN DEVELOPMENT Test case : Table

Geometry

Stress analysis

Voxelisation

Geometry

Stress analysis

Voxelisation

Geometry

Stress analysis

Voxelisation

DESIGN DEVELOPMENT Test case : Column No.2

Geometry

Stress analysis

Voxelisation

DESIGN DEVELOPMENT B.E.S.O.

When it comes to the structural optimization process (B.E.S.O.) , at first, we should decide the size of slab and the location of loads and supports. In this research, we set 4mx4m the size of slab. After that, we set a proper span of grid to deal with the variation of elements come from the structure analysis. In other word, the designers can set the size of the grid according to the size of voxel they want to make. The next step is the standardization of the vectors in each grid that come from after the structure analysis (B.E.S.O). Since B.E.S.O. can provide multiple direction of vectors in each grid, the designer need to know the average value of the vectors in each grid to simplify and replace the vector with his voxels. Of course, the voxel the designer wants to use should be designed to reflect the direction of vectors. However, no matter B.E.S.O. provides complex multiple and complicated vectors, calculating average value of vectors in a grid is simple and easy to get when the desginer use computational program, then the vectors can be revert to voxel easily. Another advantage of BESO is that since the output should be datafication in the computer program, it is appropriate to use for computational logic as well Finally, based on the B.E.S.O. data, the structure can be generated automatically by computational process.

Cantilever with initially regular mesh after application of the �BESO for Beams�-component.

LORD

LORD

30 %

SUPPORT

50 % LORD

LORD

75 %

DESIGN DEVELOPMENT B.E.S.O. Process

4M

4M

load

load

load

support

load

Floor plate

Voxelized floor plate (20 cm x 20 cm)

Vector value

Evaluating the vectors

from B.E.S.O.

Mapping with voxels

DESIGN DEVELOPMENT B.E.S.O. Process

Selected load case

Voxelized pattern

Vector field

DESIGN DEVELOPMENT B.E.S.O. Process

Simple lines

135’ 135’

Creating 3D voxels and bracing

Inside

To neighbours

Voxel + bracing lines

DESIGN DEVELOPMENT

4

3

2

1

1

2

3

4

DESIGN DEVELOPMENT

PHYSICAL FLOOR SLAB Fabrication strategy 3.90

LOAD

LOAD

3.90

SUPPORT

LOAD

LOAD

01 FLOOR SLAB DIMENSION

03 VOXELIZED PATTERN BIG : 30 CM. SMALL : 15 CM.

02 OPTIMISED PATTERN

04 GENERATED PATTERN WIRES THICKNESS : 6 MM.

05 SPL

BIG VOXELS

SMALL VOXELS B-40-a Up - Dn

UPPER LAYER

LOWER LAYER

LIT LEVEL FOR OVERLAPED CONNECTION

07 CODING STRATEGY

GAP : 6 MM.

A

1.50

2.40

B

C

D

E

1.50

0.90

1.50

06 PARTS & HANGING POINTS

1.50

2.40

0.90

1.50

1.50

08 CODED & REMOVED EMPTY VOXELS

B-40-b Up - Dn

B-40-c

B-40-d

Up - Dn

Up - Dn

PHYSICAL FLOOR SLAB Fabrication strategy

Assembling process

Stainless Steel Rope Connection