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