WIRED // R4D4 // AADRL // v04 // programmable material | robotic fabrication | design approach by George Pasisis

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Contents 5

Chapter 1: Thesis

1. Studio Brief 2. Thesis Statement

Chapter 2: Programmable Material

0. Nylon Reinforced with Spring Steel and Fiberglass 1. Investigation Process 2. Single Element Behaviour 3. Global Deformation Studies 4. Local Deformation Studies 5. Loading Test 6. Manual vs. Robotic Process

Chapter 3: Robotic Fabrication

0. Introduction and Case Studies 1. Initial Studies 2. Robotic and Material Tests 3. End-Effectors 4. Robotic Fabrication Cell

Chapter 4: Design Process 0. Introduction and Case Studies 1. Design Methodology 2. Empirical Approach 3. Numerical Approach 4. Geometrical Approach

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Studio Brief Chapter 1.1 Studio Brief The studio will explore two dominant avenues of research and knowledge, empirical layering via prototyping of human scaled spaces and objects, and scientific learning via established methods and technology from the computer graphics and computational engineering industry. The studio seeks a symbiotic relation between computer graphics, applied mathematics and architecture. It will adapt methods and technologies from these industries towards innovative use in architecture, especially those that privilege real-time interaction between the designer and the computer, and thus enabling a negotiation between â&#x20AC;&#x153;manual-craftâ&#x20AC;? and algorithmic solutions. The singular objective for these explorations would be to develop an operative design framework that synthesises the multiple formative forces of architectural space art, engineering and manufacturing. It seeks synergies between architectural articulation, engineering logics and constraints of fabrication technology.

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Metamorphosis: Prototypes as applied research in architecture, engineering and manufacturing Tutor: Shajay Bhooshan Technical Consultant: Gregory Epps

Form-finding, physical form-finding, hanging chains, soap films, etc. and associated architectural design methods as pioneered by Antonio Gaudi, Heinz Isler, Frei Otto, Felix Candela and others is common knowledge among architects. It offers, in its vast historic legacy, strong possibilities of exploring correlations between functions of design procedures and other protocols of form-finding. The studio aims to extend this work in a manner that adequately represents the ambitions and complexities of scale, digital design systems and delivery mechanisms of contemporary architectural practice. Solution Spaces: Increasing inclusion of the computer as ain in design exploration as opposed to a tool for automation of delivery processes enables the designer to widen the search for multi-objective solutions to an exponentially larger space. In recognition of this and the aforementioned ambitions of contemporary design and the pioneering work of the likes of Lionel March, John Frazer, George Stiny, etc, the studio will aim to develop design frameworks that utilise the available computational power that explores a hitherto infeasible search. Specifically the studio will utilise the conceptual frameworks, analogies to and tools of understanding natural Chapter 1 phenomena and their transcriptions to machine learning, evolutionary computing and game physics.

Studio Brief: -Z

Metamorphosis: Evolutionary processes have enabled living organisms to develop mechanisms for their morphological development, behavioural and physiological adaptations that results in their sustenance and procreation. Specific to the studio is the fact that this process of metamorphosis occurs without changing their evolved genetic code, and that they are able to change their morphology, behaviour and or physiology to enable them to adapt to changes within their life-time. In essence, the studio seeks the simultaneous the robotic processes of: morphosis, assimilation Investigationsexploration into materialofand technology has led toangroundbreaking ofproposals long-span experience into an organism; metamorphosis, an Znegative: Shajay in the field of architecture. The aim ofand the studio is to understand incorporating ability torule-based adapt to short-span in resource and theirto Booshan studio. AADRL material behaviour, calculationchanges and robotic computation applicability to designsystems and making of architecture. generate feedback capable of achieving evolution, self-regulation and self-replication. In a proposal deployed in Z negative, urban conditions Inare summary, thewhere studioultimately, will focus on theofproduction of architecture addressed aspects communication, networkingvia and anaccess understanding the critical physical processes lead to a of proposal for architecturla innovation. of formation and adaptation in nature, their control and execution by highly efficient code that in findingthe form andwishes life-cycle through a computerIn results many regards brief to adaptations address myriad aspects rising in aided, interactivearchitectural search of large solutionThemes spaces.that Thehave goal,been architecturally, contemporary discourse. explored in is the to implement processessuch and learning from Le nature through theand adaptation past, with architects as Frei Otto, Ricolais, Nervi taken into ofthe mechanisms that other such asand engineering, computer future by others suchdisciplines as Marc Fornes, Francois and Roche R&Sie(n) graphics and games have already successfully achieved. Architects. The proposal for an architecture with these parameters in mind, begins to

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Thesis statement Chapter 1.2

Investigations into materials and robotics in the field of architecture have begun to challenge the architectural discourse by proposing alternatives to conventional modes of practice through the adoption of new fabrication technologies. The aim of our research is to create a process that ensures continuity between the stage of design and the materialization of the final outcome, through the customization of industrial robotic arm technology. In order to achieve the development of a prototypical system, hierarchically connected, we have created a composite material that combines fibreglass rods, spring steel and nylon coating. In taking advantage of the force and form interaction that characterizes active-bending structures, our networked material system is deformed and through a thermoforming process the overall output is fused to produce an architecture of highresolution formation. The non-linearity of the formation process of active-bending structures, such as those generated with our material system, have led us to the development of force and materially informed structural concepts, as well as to customized form-finding techniques. More specifically, the material, initially weaved in linear strands in a planar configuration, becomes networked into a global structural system. Robotic arms elastically deform the latter, to result in a spatial formation. The geometric and structural behaviour of the networks are direct results of: material properties, initial setup topology and robotic choreography. Our research aims to investigate form-finding methodologies that satisfy structural, architectural specifications and robotic fabrication constraints. Taking for granted that the introduction of new tools in architecture alters the way we perceive and drive manufacturing, our research aims to formulate a new fabrication method that generated and addresses new formal and tectonic challenges. We contribute to the wider architectural discourse a way to develop the initial states of active-bending formations in architecture. Through integrating robotic arm technology in the construction process, we envision their potential application to larger architectural scales.

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INDUSTRIAL ROBOTIIC ARM

FIBER GLASS/SPRING STEEL/NYLON

BENDING-ACTIVE STRUCTURES

Research Frame Objectives The introduction of new tools profoundly changes the way we understand and perceive manufacturing. The use of industrial robotic arms in architecture requires investigation into new fabrication methods and generates new formal and tectonic challenges. In order to address the latter, material systems have to be reconsidered and in order to be manipulated successfully and efficiently by the new tool, they need to be understood, and their inherent malleability needs to be controlled. Overall, the implementation of industrial robotics in architecture requires a fundamental change in the early design stages, and not just a research on the possibilities of the new fabrication process.

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12 333:Architecture Summer Studio Soto,Ahlquist,Lienhard. 2014

ICD / ITKE Pavilion Menges,Knippers. 2012

ICD Textile Hybrid Menges,Knippers. 2012

ICD / ITKE Pavilion Menges,Knippers. 2012

Water and Wind Cafe Vo Trong Nghia.Binh Duong, Vietman. 2008.

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13 Flight Tanabe Kochikusai. 1983

Chandelier Prototype Kruysman and Proto, Feb. 2013.

ICD / ITKE Pavilion Achim Menges, 2012

Rainbow Bridge Yamaguchi Ryuun. 2012

Composite Surface Extruder NASA Langley Research, Dec. 2014.

Windshape nArchitects & SCAD, 2006

Moorheads Travelling chapel Marjorie Schlossman, 2001

Reference Studies Research Background Aiming to gain a thorough understanding of the selected material system and the function of the robotic arm , as well as to develop a design methodology that would be capable of creating continuity between the conceptual formation and the materialization of the final output, several case studies were conducted. A wide research on references and precedents was realized, concerning all the aspects of the project, from materials to robotics and formation processes.

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Programmable Material: Nylon reinforced with Spring Steel and Fiberglass Chapter 1.3

In our initial material experiments we use nylon reinforced with spring steel. In direct relationship with the reinforced concrete, this technique combines both, the advantages of the compressive strength of the nylon, and the tensile strength of the spring steel. The final result is a composite material in which nylon's relatively low tensile strength (45 - 90 MPa) is counteracted by the inclusion of reinforcement with steel wires which has relatively higher tensile strength (860 MPa). In the second phase of our material experiments where the global transformation is applied by robotic arms we increase the stiffness of our material by introducing Fiber Reinforced Polymers (FRP) which gives us the opportunity to scale up our material experiments from 0.9m to 2.5m and more.

different types of nylon spiral tubes that used in the material experiments

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Robotic Fabrication: Man, robotic intelligence and implicit control. Chapter 1.4

Robotic arm fabrication has once more been introduced to the architectural scene since its departure in the economic crisis of the 1980s and 90s1.. The robotic arm is a tool for fabrication with 6 degrees of freedom. Their wide use in other industries such as the automotive and airspace engineering, have made them emerged as potential players in the creative discourse. Due to mult-functionality and relatively low-price, they have begun to allow for future experimentation in architecture. End-effector design and diverse approaches to engineering have allowed for intriguing possibilities in the realm of robotic automation in construction. Robotic arms have moved past the typical uses like milling or welding and moved onto a wider range of tasks.2 In the case of this thesis, the robotic arm takes these new possible tasks and applies them to the construction and molding of a composite skeletal framework for a new proposed urbanism. "The customization, not only of the end-effectors, but also of the software interfaces, allows architects and designers to move beyond industrystandard robotic application towards highly optimized and customized machines3" - RobArc. Robotic Fabrication in Architecture, Art and Design.

1. "Rob | Arch 2012 Springer." Rob | Arch 2012 - Springer. Ed. Sigrid BrellCokcan and Johannes Braumann. KUKA Robotics and the Association for Robots in Architecture, 2013. Print. 2. Ibid. Print p.8. 3. Ibid Print. p.8.

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Design Process: Material - driven form - finding process Chapter 1.5

Taking into consideration that the generated material system structurally behaves as a bending-active structure, the design intention was focused on the observation and utilization of the interaction between force and form. The non-linearity and unpredictability that characterizes such structural systems led to the conclusion that a customized form-finding process had to be developed. Various approaches concerning design strategies were investigated, in order to obtain a wider understanding of the systemâ&#x20AC;&#x2122;s potentials and constraints, so as to be used creatively as design tools. In general, the main intention was to re-design the design system, having as an ultimate goal to create a design methodology able to take advantage of the material systemâ&#x20AC;&#x2122;s potentials as much as possible and to explore its capacities.

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Programmable Material Chapter 002

0. Nylon Reinforced with Spring Steel and Fiberglass 1. Investigation Process 2. Global Deformation Studies 3. Local Deformation Studies 4. Loading Test 5. Manual vs. Robotic Process

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It is in nature that we observe the serial, the notion of simple rules from which we derive infinitely complex systems.

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Programmable Material: Between Organicism and Computation Chapter 2.0

It is understood that at the basis of material research in architecture there should be an element of formal and programmatic logic inherent in any formation. Deeper structure, a research of materiality based on observing the behaviors of natural phenomena and translating them into coded languages, has emerged in the field to redefine both conceptual and perceptual approaches to myriad urban conditions1. In order to achieve higher levels of architectural performance, materiality has become, in its many forms and gestations, the driving force of innovation. It is in nature that we observe the serial, the notion of simple rules from which we can derive infinitely complex systems and interactions. Serial architecture questions the role of the architect; the generative parameters of any given system have been displaced by sets of digits and coded behaviors. From nature emerges notions of calculability used in order to enhance observation, and as the lens through which we interpret the physical world. Though natural formations and organic material may inspire technique, these are also generative of digital information. Historically the architect has been tempted to find in nature the forms, structural strength, diversity, and even processes, that have no man-made equivalent, with which to transform the built environment2. It is these very variables, organic abstracts which are then deployed across millions of networks and uploaded real-time by the computer. We've managed to merge the reductionist approach of the digital to the singularities of nature3. Life has become a veritable algorithm.

1. Lorenzo-Eiroa, Pablo. "Form:In:Form. On the Relationship Between Digital Signifiers and Formal Autonomy". Architecture in Formation. On the Nature of Information In Digital Architecture. Routledge. NY. USA, 2013. P.E01. 2. Picon, Antoine. "Digital Design Between Organic and Computational Temptations". Architecture in Formation. On the Nature of Information In Digital Architecture. Routledge. NY. USA, 2013. E11.01 3. Karl Chu, "The Unconscious Destiny of Capital (Architecture in Vitro/Machinic in Vivo)", Neil Leach (ed.), Designing for a Digital World (Chichester: 2002). p.127-33. Hyperzoa according to Karl S. Chu are the eruptions of artificial life that are intelligent andform part of the everyday fabric of reality. 4. Image of Project Model.

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Material Experiments Investigations into phase-changing materails that allow for innovative and unexpected results of formation.. 24

Glass-Wax:

Latex and String:

ABS and String:

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Programmable Material: Investigation Process Chapter 2.1

In order to develop a comprehensive understanding of the potentials of our composite material we execute a series of multi- scalar experiments. Within each material experiment, the complexity needs to be decoded into manageable components, determining the variable and invariable properties. To do so, each prototype can be addressed via the distinct definitions of topology, transformation (global and local) and materiality. Such definitions establish the character of the system, where integration generates the behavior.

left: basic material characteristics and steps of the robotic fabrication process

basic diagram of the investigation process in terms of programmable material

More specifically, the material, which initially is formed in straight strands of multiple wires weaved together, becomes networked in a global structural system. In continuation, the robotic arms elastically deform the latter, producing complex geometry by applying simple Euclidian transformations at specific points. The geometrical definition and structural behaviour of this deformed network are directly influenced by the characteristics of the material, the initial setup topology and the robotic movement. Finally, through a thermoforming process, we fuse/ freeze the structure into the overall formation. During this process customised robotic end effectors are used for the fabrication.

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The manual experiment process includes analytically the following steps: - Preparation of the framework Our framework is composed by plates having a pattern of holes from which wires are passing. We investigate the results produced by frameworks in which the wires between the interacting planes are weaved in different ways and different densities.

- Initial material configuration - weaved wires - spiral nylon tubes as an exterior layer - From solid to malleable state- nylon's heat deflection temperature= 60째C - Application of basic Euclidean transformations to the plates - translation (x, y, z) / rotation or combination of those.

The final deformation is relative to the initial setup (topology), the applied forces (global transformation), the plane normal (global transformation), the heating temperature and the heating time (local transformation). - Hardening procedure We stabilize the experiment allowing to act only gravitational forces in our system. The time period of hardening is approximately 60 minutes. The wires are embedded passively in the nylon. In this system we observe two kinds of material deformation, the global based on the wires' behaviour because of the external forces that we apply and the local based on the deformation of the nylon due to the heating process. We freeze the transformation of the wires using the nylon's deformation. We can predict in some extent the global deformation based on Young's modulus which enables the calculation of the change in the dimension of a bar made of an isotropic elastic material under tensile or compressive loads. left: weaving pattern of the plates right: global elastic deformation of the wires based on Young's modulus

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Programmable Material: case studies

In this section we look into material performance (elastic behavior) so as to understand the results of the active bending behavior. Bending active structures utilize a material's capacity to bend elastically and generate curved geometries from initial straight or planar configurations. Various construction methods known from vernacular architecture make use of the elastic behavior of their building materials, leading to a recognized construction type which prevails in some cultures and certain applications. BAMBOO MASTERS Among these the Japanese bamboo art of baskets. Talented artist like Yamaguchi Ryuun, Shono Shounsai and his student Tanabe Kochikusai generate some of the most complex curved geometries in the history of bamboo masters using the elastic bending behavior of the material to convert simple Euclidian straight lines to non-Euclidian geometric setups. RESEARCH PAVILION ICD/ITKE 2010 At the end of July 2010 the Institute of Computer based Design (ICD) and the Institute of building structures and structural design (ITKE) at the University Stuttgart realised a temporary research pavilion made of plywood. The design of the pavilion was the result of a student workshop which focused on the integration of physical experiments and computational design tools to develop bending-active structures. The Pavilion structure is based on a radial arrangement and interconnection of the self-equilibrating arch system made ply wood. TEXTILE HYBRID M1 The Textile Hybrid M1 at La Tour de l' Architecte showcases the research on hybrid form- and bending-active structure systems by the Institute for Computational Design (ICD) and Institute for Building Structures and Structural Design (ITKE) with students of the University of Stuttgart. The scientific goal of the project was the exploration of formal and functional possibilities in highly integrated equilibrium systems of bending-active elements and multi-dimensional form-active membranes (termed Deep Surfaces). The resulting multi-layered membrane surfaces allowed not only for structural integration, but also served as a functional integration by differentiating the geometry and orientation of the membrane surfaces.

source: Form-finding bendingactive structures with temporary ultra-elastic contraction elements / J. Lienhard, R. La Magna, J. Knippers

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Programmable Material: single element behavior global deformation studies Chapter 2.2

In this experiment we are focusing in the behavior of a single spring steel under different loading forces. We use two different thicknesses (0.64mm and 1.4mm - changing in the stiffness) and two different lengths (100mm and 200mm) of piano wires of circular cross section. What we found interesting is the elastic deformation of the wires which we can easily actuate and adjust according to the different loading conditions in the anchor points.

left: loading of single wires - process of the experiment

The thin wire stores elastic potential energy as it is deformed. This energy is not distributed equally, but increases towards the middle where it reaches a maximum. If this energy exceeds the elastic bending radius of the material the wire will deform plastically. The parameters that we change are the global deformation in terms of the applied forces in the anchor points and the material (different lengths and thicknesses).

simulation of the elastic deformation of a single member based on particle spring system matrix parameters: initial angle, length and stiffness The Rise - Alive Exhibition, EDF Foundation 2013, Paris

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Programmable Material: single element behavior local deformation studies

In this experiment we are focusing in the behavior of different nylon tubes in term of thickness under similar heating conditions. Thermoplastics, such as nylon, shrinks in length when heated, while expanding in width. When the material is cooled, it returns to its original length. We use three different thicknesses 3mm, 8mm and 12mm heating them individually but also all combined. Our task is to calibrate the heating time so as to achieve the desired local deformation. The heating time in the individual experiments is 60s and in the combined is 120s.

left: the final formation of each spiral nylon tube after the thermoforming process

The parameters that we change are the local deformation in terms of the applied heating time and the material (different thicknesses). detail of the weaved wires before heating process combination of different thicknesses

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Programmable Material: global deformation studies low resolution experiments Chapter 2.3

In this series of experiments we combine the two different materials being used, the spring steel and the nylon in a series of low resolution setups where we apply similar global and local deformation. Apart from the interesting formation of the final geometry which is a result of the interaction between the two materials, we quickly realize that there is a difference between the results because of the way that the forces are applied to the anchor points. A precise control of those forces becomes necessary.

left: the final formation of each low resolution material experiment after the global and local deformation

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Programmable Material: global deformation studies translation in the xy plane

In this series of experiments we investigate the global transformation of the wires by translating- moving the anchor points of the material setup (theoretically the end effectors plates) in the XY plane. The process is manual without the use of any robotic arm and aims to understand the material's behaviour and the resulting geometry.

left: the sequence of applying global and local deformations that results a two branches system

The parameters that we change are the initial topology and the global deformation in terms of the applied forces in the anchor points. The result is a branching system

Initial experiment: before and after applying deformations

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final height initial - final h max expand wire density nylon 3mm nylon 8mm

split 2

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diagram 1

Image of the final state of the experiment 1 -1 - 2 Basic parameters information Base plate weaving pattern Linear diagram of the final state Deformation of the wires based on Young's Modulus

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final height initial - final h max expand wire density nylon 3mm nylon 8mm

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Image of the final state of the experiment 1 -1 - (3 +1) Basic parameters information Base plate weaving pattern Linear diagram of the final state Deformation of the wires based on Young's Modulus

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final height initial - final h max expand wire density nylon 3mm nylon 8mm

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Image of the final state of the experiment 1 -1 - 4 Basic parameters information Base plate weaving pattern Linear diagram of the final state Deformation of the wires based on Young's Modulus

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Initial state: wires and nylon configuration before the heating process.

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Programmable Material: global deformation studies translation: z axis / rotation

In this series of experiments we continue to investigate the global transformation of the wires by applying basic Euclidian transformations in the anchor points of the material setup. We concentrate on the translation in the Z axis (compression of the wires) by reducing the distance between the anchor points- end effector's plates. We also introduce rotation of the plates around the Z axis which passes from the center of gravity of the geometry. The second experiment is double the size of the first one, and we use the double amount of material (scale factor 2). The process is manual without the use of any robotic arm and aims to understand the material's behavior.

left: the sequence of applying global and local deformations that results a spiral system

The parameters that we change as a result of the change in scale are the initial topology and the global deformation in terms of the applied forces at the anchor points.

diagrammatic representation of the robotic movement- collaboration producing a spiral geometry translation in Z axis + rotation

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final height initial - final h max expand wire density nylon 3mm nylon 8mm

spiral 1

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Image of the final state of the experiment spiral 1 : 2 Basic parameters information Base plate weaving pattern Linear diagram of the final state Deformation of the wires based on Young's Modulus General Setup

diagram 6

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Initial state: wires and nylon configuration before the heating process.

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final height initial - final h max expand wire density nylon 3mm nylon 8mm

spiral 2

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Image of the final state of the experiment spiral 1 : 1 Basic parameters information Base plate weaving pattern Linear diagram of the final state Deformation of the wires based on Young's Modulus

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lattice formation and branching system as a result of the accumulation of material in specific areas

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Programmable Material: global deformation studies same transformation different sequence

In this series of experiments we continue to investigate the global transformation of the wires by applying basic Euclidian transformations at the anchor points of the material setup. We use the same transformations (translation in all axis and rotation in xy plane) but applied in different sequences. As expected the resulting geometries are different in terms of global deformation. The parameter that we change is the global deformation whereas all the other parameters remain the same.

left: the sequence of applying global and local deformations that results a 4 braches geometry

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Image of the final state of the experiment 4- 1- 4 Base plate weaving pattern Linear diagram of the final state Deformation of the wires based on Young's Modulus

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Image of the final state of the experiment 4- 1- 4 Base plate weaving pattern Linear diagram of the final state Deformation of the wires based on Young's Modulus

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Programmable Material: local deformation studies different heating time Chapter 2.4

In this series of experiments we investigate the local deformation of the nylon by changing the heating time. Even if all the other parameters are remaining the same we observe that the local deformation of the nylon influences the global result. The process is manual without the use of any robotic arm.

the sequence of applying global and local deformations that results a spiral system

The parameter that we change is the local deformation.

detail of the different global result in the third experiment of this series

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final height initial - final h max expand wire density nylon 3mm nylon 8mm

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Image of the final state of the experiment H1 Basic parameters information Base plate weaving pattern Linear diagram of the final state Deformation of the wires based on Young's Modulus

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final height initial - final h max expand wire density nylon 3mm nylon 8mm

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Image of the final state of the experiment H2 Basic parameters information Base plate weaving pattern Linear diagram of the final state Deformation of the wires based on Young's Modulus

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final height initial - final h max expand wire density nylon 3mm nylon 8mm

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Image of the final state of the experiment H3 Basic parameters information Base plate weaving pattern Linear diagram of the final state Deformation of the wires based on Young's Modulus

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Initial state: wires and nylon configuration before the heating process.

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Programmable Material: loading test Chapter 2.5

In this experiment we are testing the strength of the same component in compression forces. Compressive stress (or compression) is the stress state caused by an applied load that acts to reduce the length of the material (compression member) along the axis of the applied load. A part of the applied forces, because of the components geometry is translated to transverse loading. This causes the members to bend and deflect from its original position, with internal tensile and compressive strains accompanying the change in curvature of the member.

left: loading experiment of a spiral prototype and its' elastic deformation

In materials science, the strength of a material is its ability to withstand an applied load without failure. In the last experiment the component can with stand a total loading force equal to 245N.

investigation of the temporary deformation of a straight column under loading compression force of 75KN and exposure to heat for half an hour (2000W) initial - final height= 30mm

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Programmable Material: manual VS robotic process Chapter 2.6

In this series of experiments we investigate the difference between the manual and the robotic fabrication process. The basic parameters remain the same, like the initial setup, the heating time and the applied forces. Finally we compare the results in terms of deformation of the final product.

right: the initial state of the material experiment plates attached to the robotic arm

Even if the global deformation and the bounding boxes of both products are similar, in local scale the difference is dramatic. In the robotic fabrication the transformation of the wires appears to be more uniform in comparison with the manual process. This happens because of the uniform distribution of forces in the plates, which is then transmitted to the wires.

preparation of the robotic experiments at Robofold LTD.

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Resulting geometries form experiments: Straight and 1- 1- 3 Column Height: 90cm

the

manual

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Image of the final state of the experiment Basic robotic configuration Final robotic path- planes

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Image of the final state of the experiment Final robotic path- planes

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summarizing the process of the material experiments

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Robotic Fabrication Chapter 003

0. Case Studies 1. Initial Studies 2. Robotic and Material Tests 3. End-Effectors 4. Cell Design

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Robots in Architecture Chapter 3.0

77 In the last decade the development of technology has led to the discovery of many new techniques of construction, 3-D printing and Robotic arm fabrication being the most highlighted outcomes. The usage of robotic arms in the industrial sector production in the previous years laid base to this innovative idea of using them in architecture. Thereby creating possibilities of fabricating complex geometries using these arms through the medium of coding and extensive software application. Many firms such as Gramazio & Kohler, Robofold, Bot and Dolly have collaborated with world renowned architectural schools, researchers and leading names in the profession to create outstanding structures and complex installations, using the innovation to the maximum. Therefore highlighting the applicability of these robotic arms as the future of the evolving construction and fabrication industry.

IMAGE 1 - GRAMAZIO & KOHLER NYC

IMAGE 2 - ZHA PAVILION VENICE BIENNALE

Learning from the achievements of the above mentioned structures and their fabrication process, we desire to apply the same in our thesis project of customized robotics. Using the material intelligence and the feedback generated, exploring the ways in which the robotic arm could be used to fabricate the structure in the prototypical conditions is the goal.

IMAGE 1 "GRAMAZIO & KOHLER: DIGITAL MATERIALITY." WHAT WE DO IS SECRET. N.p., n.d. Web. 10 Apr. 2014. <http:// www.whatwedoissecret. org/madebyblog/2009/09/ gramazio-kohler-digitalmateriality/>. IMAGE 2. Urschler, Matthias. Urschler, Matthias. "WHAT | we did summer 2012 , Venice - AA Visiting school , Bangalore 2013." WHAT we did summer 2012 , Venice - WHAT | we did summer 2012 , Venice -N.p., n.d. Web. 9 Apr. 2014. <http:// www.zha-code-education. org/WHAT-we-did-summer2012-Venice>.

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Precedents : The 2012 Research Pavilion Achim Menges

78 THE RESEARCH PAVILION 2012 The Research Pavilion was built in November 2012 by the Institute for Computational Design (ICD) and the Institute of Building Structures and Structural Design (ITKE) at the University of Stuttgart led by Achim Menges. It was completely fabricated by a single 6-axis robotic arm using carbon and glass fiber composites. This interdisciplinary project, conducted by architectural and engineering researchers of both institutes together with biologists of the University of Tbingen, investigated the possible interrelation between biomimetic design strategies and novel processes of robotic production. The research focused on the material and morphological principles of exoskeletons of arthropods as a source of exploration for a new composite construction in architecture.1 The project transferred the fibrous morphology of the biological role model - the exoskeleton of the lobster (Homarus americanus) (which was analysed in greater detail for its local material differentiation) to fibre-reinforced composite materials, the anisotropy of which was integrated from the start into the computer-based design and simulation processes,.

1 - "achimmenges.net - Achim Menges Design Research Architecture Product Design." achimmenges.net - Achim Menges Design Research Architecture Product Design. N.p., n.d. Web. 8 Apr. 2014. <http://www.achimmenges. net/?p=5561>. 2 - Ibid.

IMAGE 3 - PAVILION FABRICATION

IMAGE 4 - RESEARCH PAVILION 2012

The lobsters exoskeleton (the cuticle) consists of a softer endocuticle, and a relatively harder exocuticle. The specific position and orientation of these fibers and related material properties relate to specific local requirements. In areas where a non directional load transfer is required, the chitin fibers get incorporated into the matrix by forming individual unidirectional layers laminated together in a spiral arrangement forming an isotropic structure which helps in uniform load distribution throughout. And the areas which are subject to directional stress, a unidirectional layer structure is exhibited, forming an anisotropic assembly for direct load distribution. Due to this local material differentiation, the shell creates a highly adapted and efficient structure. These principles of locally adapted fiber orientation constituted the base for the computational form generation, material design and manufacturing of the pavilion.2

3 - Ibid IMAGE 3 - achimmenges. net - Achim Menges Design Research Architecture Product Design." achimmenges.net - Achim Menges Design Research Architecture Product Design. N.p., n.d. Web. 8 Apr. 2014. <http://www.achimmenges. net/?p=5561>. IMAGE 4 - Ibid

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IMAGE 5 - ANISOTROPIC FIBRE ORIENTATION

IMAGE 6 - ISOTROPIC FIBRE ORIENTATION

FABRICATION After the thorough research, a fiber composite system of resin saturated glass and carbon fibers was employed in weaving the anchored temporary light steel frame which formed the mold of the pavilion. The 6 -axis robotic arm instead of having to move around to place the fiber was coupled with a digitally controlled turntable which was rotating the whole pavilion's structure, while the robotic arm was just moving the filaments. The pre-stressed fibers were tensioned between the anchor points and from the straight segment of these fibers emerged the double curved shape of the pavilion. In this way the hyperbolic paraboloid surfaces resulting from the first sequence of glass fiber winding served as an integral mold for the subsequent carbon and glass fiber layers with their specific structural purposes and load bearing properties. The glass fibers were mainly used for spatial partitioning and the carbon fibers contributed primarily for the load transfer and the global stiffens of the pavilion..3 Fiber optic sensors were also integrated into the structure which continuously monitored the stress and strain values so as to regulate the fiber placement such that their orientation gets optimally aligned with the force flow in the skin of the pavilion. The arm was placed on a 2m high pedestal which allowed it to a working span of 4m. Since the control of the robot was highly explicit in this scenario many virtual iterations and simulations of the same were generated and compared before the final structure which spanned 8m in dia and 3.5m was erected and it consisted of 30 km of fibre rovings.

IMAGE 7 - ISOTROPIC & ANISOTROPIC FIBRE ORIENTATION

IMAGE 8 - FIBRE WEAVING

IMAGE 5 - achimmenges.net - Achim Menges Design Research Architecture Product Design." achimmenges.net - Achim Menges Design Research Architecture Product Design. N.p., n.d. Web. 8 Apr. 2014. <http://www.achimmenges. net/?p=5561>.

IMAGE 6 - Ibid IMAGE 7 - Ibid IMAGE 8 - Ibid

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Precedents : The Chandelier Prototype Kruysman and Proto

80 THE CHANDELIER PROTOTYPE This project was fabricated in 2013 by Jonathan Proto and Brandon Kruysman at the Sci-Arc robot house. The bottom up approach consisted of 3 stabuli robots choreographed using Esperant.o software to fabricate a chandelier made of plastic tubes, highlighting the collaboration of the robotic arms, each performing a certain task. The complexity of the project lies in the networking of the three arms which were simulated virtually and physically simultaneously to achieve the end result, invariably testing the heat fusing and material deformation process. FABRICATION It consisted of three arms as mentioned earlier, where one robotic arm was choreographed to pick up the plastic tubes from the dispenser and rotated it, while the other arm heated the tube using the heat gun as an end effector. Once heated, the arm holding the tube would then place it on the stack, melting and fusing with the tubes which were laid earlier. The third arm then consisting of a spray gun would spray the coloured coolant on the rim of the placed plastic tube.

IMAGE 9 - THE CHANDELIER PROTOTYPE

The project is of great interest, since it speaks of the level of precision and control that can be obtained through the choreography of multiple robots. Even though the control on the deformation of the material on heating was limited but the amount of heat applied and the time period could be realised.. Moreover the designers experimented to develop a form finding process through the generative logic by giving up control on the material deformation.

IMAGE 9 - "SCI-Arcâ&#x20AC;&#x2122;s Robot House Gets Hot | Los Angeles, I'm Yours." Los Angeles Im Yours. N.p., n.d. Web. 8 Apr. 2014. <http:// www.laimyours.com/20418/ sci-arcs-robot-house-getshot/>. IMAGE 10 - Ibid. IMAGE 11 - Ibid IMAGE 12 - Ibid

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IMAGE 11 - PLACING THE HEATED TUBE

IMAGE 10 - SPRAYING THE COOLANT

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Opportunity for Development

Industrial Robotic Arm Tools and Cells 82

1. Brell-Cokcan, Sigrid, and Johannes Braumann. Rob/Arch 2012: Robotic Fabrication in Architecture, Art and Design. Wien: Springer, 2013. Print. IMAGE (across) 1. Tesla Robotic Arms constructing automobile machinery. http://image. motortrend.com/f/features/ consumer/1206_temple_ of_tesla_touring_elons_ factory/38156267/tesla-multitasking-robots.jpg

Architectural research into robotics does not aim to change the machinery, but its use in regards to built space and fabrication1. Digital and material processes are brought together by means of robotic engineering, and given new meaning consequently to the combination of these two worlds. Fabrication thus, is not the only aspect addressed in robotic manufacture, but generation of new viable building systems by means of highly organized and complex concepts. Our aim is to develop a seamless integration between digital and material processes that will render as its outcome, a viable proposal for deployment. Robotic automation is but the key for aspects of repeatability, speed, and regeneration. The use of robotic arm technology is not a matter of reinvention but of re-purpose. We are using machinery that is employed in other fields to redefine what architectural automation means. With all the advantages of a robotic arm, we hope to generate a system that is sophisticated, responsive and structurally adept at generating new environment.

Electronics Milling

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SOFTWARE RIOS SSC - 32 MAYA IK Handle Godzilla Plugin

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To understand the flexibity and the space occupation of the virtual robotic arm in the three axes Maya simulations were conducted, where the arms were made to follow simple and complex geometries.

SEQUENCE 1 AXIS - X AXIS SHAPE ARM RADIUS - 1.08m

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In this iteration the space occupied by the motion of the secondary arm is also analysed.

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The initial studies using the lynx motion al5d arm concentrated mainly on understanding the robotic movement, distance control using motion sensor attached to the arm and the co-ordination between two robotic arms. 98

1 Robotic Movement

The robotic movement study shows the initial simualtion using robots IO software. The movement involves the arm picking up and dropping the candy into the coffee mug. Once tested the simulation is then fed into the physical robot as seen in the sequence below.

2 Distance Control

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The distance sensor helps in maintaining a constant distance between the material and the robotic arm which becomes useful especially during the process of heating. If the robot appears too close to the material than the desired distance, then the distance sensor helps the robot in re-adjusting the distance between the material and the end effector.

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3 Robotic Co-ordination

The above sequence shows the process of robotic coordination using two Al5D robot arms. The process is programmed using the godzilla plugin for grasshopper as shown in the initial sequence(A-C). It involves the material system being heated from a constant distance of 5cm, while the robots rotate the suspended material to ensure uniform heating(D-F). The robots then rotate in the opposite direction to enable the twisitng( global deformation) of the material system, while the phase changing occurs due to heating.(local deformation) as shown in the sequence(G-L).

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In this sequence the AL5D arm was choreographed to see the accuracy with which it can reach a certain point and lift a foam brick, perform certain movements and place it back again onto the same point.

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The AL5D arm was choreographed to understand the path it could traverse accurately BETWEEN TWO POINTS along the 60 degree angles in the X and Y axis.

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The choreography was executed using the default software provided by Lynx Motion. A virtual simulation of the same movement was also designed using Godzilla plug-in for Grasshopper. SEQUENCE 1

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LONG EXPOSURE PHOTO OF SEQUENCE1 PATH 1C

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Fig. Above Images of KUKA KR150-2 IAAC Workshop. Movement and End Rotation

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Fig. Above Images of KUKA KR150-2 IAAC Workshop. Components

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The reach map analyses the reach of a robotic arm within an enclosed space. It establishes the points which the robot can traverse through easily and where it cannot. In this instance of a cube, the robotic arm traverses through 730 points during which at various points, the different axes of the robots get highlighted depending upon the conditions of:

Singularity

Out of reach

Axis out of range of rotation

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The diagrams decode the volume into the three axes and explain the points of convenient and difficult robotic reach in the same.

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Movement Of Axis in Space [3]

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Differentiated Grid - Angles

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The axesaxes on the The sequence sequence below belowshows showsthe themanual manualactuation actuationofofthe thefive three on dethe sign study model, thatthat leadlead to the up ofup theofstructure. HenceHence these design study model, to popping the popping the structure. five become the essential movements of the robots the fabrication (pop these five became the essential movements of the for robots for the fabricaup) of theup) structure. tion(pop of the structure. Movement in X axis

Rotation in X axis

Movement in Y axis

Rotation in Y axis

Movement in Z axis

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Robotic and Material Fabrication Tests 3.2

1. First Test 2. Second Test 3. Third Test

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The Three Tests Developing the System Figures opposite: The demonstration of the active-bending behavior underwent a series of tests both materially and robotically. The three tests performed developed all aspects of the system simultaneously.

The three robotic tests performed were done in order to test the concept of bending, the anchor point, the control points of the material, and principally, the material integrity itself. First Test: The four strand test, was the first scale up model of the system. Here the most essential test was the material, which was proven to be too heavy to overcome its own weight, let alone gravity. Bending behavior of the material scaled-up did not successfully achieve a pop-up quality. Second Test: The second test incorporated the reinforcement fiberglass. The fiberglass in this particular scenario formed a cage around the existing plastic and spring steel composite. The anchor point and control point aspects were tested along-side for robotic coordination. Third Test: The last test used the fiberglass as a core, allowing the material strand to have a hollow core. This was the most successful of the experiments. The strand lifted and behaved successfully in activebending.

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First Test Four Column Test Figures top and opposite: Series of frames illustrating the process undergone in the first test of the system. The robotic arms push the material to transform it. The material is seen failing.

The initial test performed at a large scale meant to prove whether the material composition of the system could actually behave as hypothesized. The greatest failure of the system at this time had to do with the composition of the material itself. Though spring steel is a material adept at active-bending, it does not overcome its own weight or gravity when the length is increased. In reality the strands had a difficult time to both set in formation and to achieve bending of any kind. The structure was manually pushed and pulled as much as it was robotically formed. The conclusion achieved was to further develop the material by adding reinforcement. By adding another material that could bend at this scale and withstand the pushing force applied by the robotic arms.

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Photograph of the final state of the first material and robotic test. This test led to the updates of both robotic and material systems. Particularly evident is the structural quality of the spring steel.

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Results:

The outcome of the first test, though proving our hypothesis erroneous, did lead to some of the largest developments in the project. The model based solely on spring steel as its main structural element proved that it could not overcome its own physical weight, let alone gravity. It was understood that as the material scale changed, so must the composition of the strand itself. It was concluded that at this point another type of material had to be introduced. The most logical material, one that behaved similarly to spring steel, was fibre glass. Its strength and elasticity being similar allowed for a reinforcement in the strand, and a material strong enough to endure the forces applied by the robotic fabrication.

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Second Test Fiberglass Cage Reinforced Column Figures top and opposite: Series of frames taken during the second test. The robotic coordination and material behavior's improvement is evident in the outcome of the test.

This test was concerned with developing two aspects of the system: the robotic coordination of control point and anchor point, as well as the material which was reinforced with fiberglass. In the material aspect, the fiberglass was added to reinforce the column and allow for the material to sustain a scale-up. In this particular test the fiberglass proved to not only support the column, but to self-support the strand. In essence, the material reacted favorably to the added force applied by the robotic arms. The robotics also tested the logistics of control points on curves, where the strands bending behavior could be guided by the movement of the tool. The mechanical gripper was used in this occasion to allow for the manipulation of the material on the part of the robotic arm.

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Third Test Fiberglass Core Reinforced Column Figures top and opposite: Series of frames taken during the third test. The robotic coordination and material behavior's improvement is evident in the outcome of the test. .

The third experiment used the fiberglass reinforcement as a core component of the material. Active-bending was successful in this case due to the fact that the material could not only endure the forces applied by the robotic arms, but allowed for elastic deformation. In many regards, this was a successful scale-up of the system. The hardest and most demanding component was the generation of the strand itself, due to the weaving of not only two, but three diverse materials, in order to assemble the overall composition of the final strand as it would be proposed for the system.

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Conclusions Fiberglass, Spring Steel and Nylon Composite Figures top: The layout of material for both the second and third tests. Figures opposite: The strands before the deformation and heating and after, showing the areas of failure and fracture in the material.

Global Deformation: The main problem of the material in the second test was principally due to the fact that the fiberglass endured too much stress and was weakened during the heating process. As fiberglass has a failure temperature of approximately 1750 oC, the heat applied for too long surpassed its point of failure. Though with heat it can be molded to take another form, sustained heat will cause it to break as well. In the case of the experiment, the strand suffered global deformation that made it structurally inadequate. Local Deformation: The third test not only reduced the amount of failure of the fiberglass, but proved to be a more than adequate structural material. The failures in the fiberglass were reduced to minimal local fractures and the integrity of the material remained intact allowing for the offset hollow fiberglass rod core to achieve active-bending while deformed by the robotic arms.

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Close up of strands after local heating

On the right, the picture highlights the different material behaviour of the two different strand set-ups. In the first case where the fibreglass rods are placed at the exterior layer of the strand there is a global failure / plastic bending of the rods. In the second case on the contrary, where the fiberglass rods are placed in the core of the strand and covered by the weaved wires and nylon, only local failures can be observed that donâ&#x20AC;&#x2122;t affect the overall geometrical configuration. This is due to the fact that fibreglass rods are not heat resistant and when exposed to high temperature they loose their structural capacity. Consequently in the second experiment the exterior layer of nylon and wires acted as a protection.

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After testing indvidual strand set-ups, a scaled-up networked version of those was fabricated using industrial robotic arms. More precisely the length of the strands was set at 3mts and the network structure consisted of 8 strands. The addition of fiber glass rods in this experiment was of crucial importance due to structural performance issues. Therefore the initial setup had to be reconfigured to support the weight of the 8 strands. The design of the network of the 8 strands played a significant role as it determined the constraints that led to the final geometrical configuration after the active bending deformation performed by the robot. The material of the experiment was set up manually in a flat configuration where the nylon and the spring steel cables were weaved in a specific pattern around the fiber glass rods. The global deformation of the overall setup was predicted through a digital simulation in order to visualize the active bending behaviour of the strands due to the robotic actuation. The local deformation of the setup was performed manually. The heating of the nylon tubes set the deformation in space and fused structure in an overall configuration.

Left. Close up of the scaled-up model. Showing the material organization detail.

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Network Iteration. 1 Bending configuration High level of constraint Cross/Tangential connections

Iteration .3 Straight configurations High level of constraint Mostly tangential connections

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Iteration .2 Bending configuration Medium level of constraint Cross/tangential connections.

Iteration .4 Straight configuration High level of constraint Mostly cross connections

Bending Behaviour Network Setup A series of physical experimentation concerning the intial network setup where realized in order to find the optimal solution with the most three dimensional characteristics.

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After selecting the optimal network a digital simulation of its active bending behaviour was realized in order to visualize the final outcome. Similarly a physical model of the same setup was made in order to verify the accuracy of the latter.

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The setup of each individual strand consist of ten fibre glass rods in a circular array at the core and 50 spring steel wires weaved around them. All of those are coated in nylon tubes which are later fused by heat to solidify the composite strand.

Scaled-up Material Experiment Setup Detail of the base holding each strand.

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Close up of strand network before local heating

Before the local heating of the strands the network shows no structural capacity. In the picture to the right the spring steel wires can be observed in their relaxed configuration.

MATERIAL EXPERIMENT DETAILS: Number of Strands: 8 Number of connections: 10 Number of fixed anchor points: 8 Number of actuated anchor points: 2 Total length of fiber glass rods: 160 m Total length of wires: 800 m Total length of nylon: 960 m

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Customizing the System Designing the End-Effectors Figures top: The three end-effectors mounted on the robots. Opposite: Diagram of the overall automation of the process. End-effectors

The end-effectors of the system were developed to automate the entire process proposed by the material process and the architectural intentions. In essence the three aspects that were considered for customization were: Material Generation, Global Transformation and the Setting Process. Material Generation: The material is meant to be generated by the end-effector and the robotic movement. As the end-effector weave the material into one composite strand, the robot places it where it must be for its subsequent transformation. Global Transformation: The transformation end-effector relies on previous robotic information of material deposition. Once the strands are in place, robotic movement itself defines final shape. Setting Process: The setting process targets local deformation, the nylon is melted and set in order to give the architectural construct its final form.

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Weaving Tool

Gripping Tool

Heating Tool

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The Gripping End-Effector

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The Weaving End-Effector Chapter 3.3.1 Generating the Material Figure: The robotic arm and end-effector during the initial testing of the material generation process.

The generation of material was not only one of the most essential parts of the system proposed in the project, but was also one of the programmable aspects of the architectural contention. In reality, the creation of a weaving end-effector not only impacted the type of end-effectors incorporated in the system, but the overall ability for architecture to be adapted in-situ -an architecture of place and instance.

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LEXUS LOOM The circular loom of the automobile industry Lexus is developed to weave strands of CFRP (carbon fiber reinforced plastic) into three-dimensional shapes. It is used to weave dual-tube carbon fiber components, like the A-pillar and it costs about $400,000. CARBON CANDY Carbon Candy is a research project by John Klein, Robbie Eleazer and Yaohua Wang that explores additive manufacturing processes with UV curable composite tapes. The project placed as a finalist in the Machineous Robotics Competition in Los Angeles. The project is theoretical. ISAAC ISAAC (Integrated Structural Assembly of Advanced Composites) is a 21-foot tall robotic arm that can move along a track, and lay down preimpregnated reinforcing fiber, such as carbon fiber. NASA acquired it, at a cost of $1.7 million. ISAAC was delivered on Sept. 30, 2014, moved into its rails on October 14, and began laying up composites on Dec. 3. ISAAC can build composite parts by depositing sticky, pre-impregnated carbon fiber at very precise positions and angles. This precision will allow objects â&#x20AC;&#x201C; parts of a space vehicle, for example â&#x20AC;&#x201C; to be reinforced in ways that conform more closely to the actual flow of loads in the part when it is in use. This maximizes the efficiency of the reinforcement and potentially reduces weight and materials cost.

left: photos of the case studies

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In this series of prototypes we investigate the planetary gear logic, in which through only a single input we can have multiple outputs. We start with three planetary pinions that are in mesh with the sun gear at all times. The three gears are free to rotate on individual shafts on the planet carrier, which is a framework designed to hold the pinions in their respective positions. The planet carrier can be rotated so that the pinions walk around the sun gear. The carrier also contains a shaft so that it acts both as an input and output member. The outer internal gear is in constant mesh with the planet pinions and is called the ring gear. The principle on which the planetary gear set operates is based on driving one unit, holding one unit, and taking the output from the free unit. In the second experiment we try to multiply the outputs from four to seven by adding three planetary pinions in the system. By having all the gears in the same level we realize that the friction is increased to levels that we cannot overcome. In the second phase of this prototype we split the planetary pinions in two groups, we position them in two different levels and add another sun gear to the system, parallel to the first. The result is that the system works perfectly now having the same rotation input as before. In the third experiment we add another planet pinion carrier and we optimize the shape and the number of the teeth of the gears so as to reduce the friction. There are five basic rules of planetary gear operation: -If the planet carrier is used as the output, the set operates in reduction (slower speed, more torque). -If the planet carrier is the input, the set operates in overdrive (more speed, less torque). -If the planet carrier is held, the set operates in reverse. -If any two parts are locked together, the set operates in direct drive. -If no parts are locked together and if none are held, the set operates in neutral. We choose to hold the ring gear from turning. By doing this the planet pinions will have to rotate on the interior of the ring gear and the exterior of the sun gear. Additionally the planet pinions will carry the planet carrier around with them. We thus apply this logic in the following prototypes of the weaving endeffector.

left: the sequence of operation of the three different planetary gear prototypes

planetary gear system main parts

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In this version of the end effector we develop a model based on the planetary gear logic where there is only one input, three main and one secondary output. This technique is also famous as a traditional rope making technique. The basic components of the weaving machine are: -a frame, which handles the mechanisms and features -an internal gear -3 planetary devices which support 1 reel each and can also rotate -3 reels, one in each planet pinion which can also rotate -1 disk with 3 holes for weaving 3 strings in one attached to the sun gear In each of the main outputs we attach one reel of thread that follows the movement of the respective planetary gear. The final twisting result is produced through the movement of the sun gear, in which the end points of the thread of each reel are attached to. This model produces a low resolution result of only three threads (different material) and has no control over the weaving pattern.

left: the sequence of operation of the first version of the weaving end- effector

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basic components of the weaving end effector v01

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In this version of the end effector we continue based on the same principle of the planetary gears. In comparison with the previous one we multiply the outputs to 42 in total and we also achieve to change the weaved material from threads to spring steel. So we achieve to get close enough to our real material experiments complexity in terms of material and number of weaved wires.

left: the sequence of operation of the second version of the weaving end- effector

Each of the end points of the wires is connected to one of the six holes of the 7 disks which are attached as output to the respective planet pinions. To multiply the outputs, from 3 to 6 planet pinions we use the logic of the third prototype of the initial planetary gear investigations. This model produces a relatively high resolution result but has the disadvantages of the finite length of the used wires (because of the attachment of the end points to the disks) and the manual rotation which still exempts control over the weaving pattern.

planetary gears in operation

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integral gear planet pinion output x6x6 sun gear output x6 planet pinion carrier

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1 input (6+1)x6= 42 outputs weaving pattern

basic components of the weaving end effector v02

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In this version of the end effector we continue based on the same principle of the planetary gears. The tasks are to achieve a theoretically infinite weaved strand by feeding the machine from the rear and also to automate the rotation force. To achieve the first task we introduce hollow tubes as the main outputs of the planet pinions and the sun gears. This facilitates the wires to be passed through the system, straight form the one side and weaved from the other, without any difficulties. The second task is achieved by adding a wiper motor, which is connected to an external electrical supply, and linking it with the main system through a chain.

left: the sequence of operation of the third version of the weaving end- effector attachment to the robotic arm

The machine after some modifications of the frame is attached to an industrial robotic arm where as a proof of concept wires without the nylon coating are weaved in straight strand of 1.8m length.

principle of operation and main parts of the weaving end effector

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Weaving end-effector details Figures top and opposite: 3D digital model showing the various components and mechanisms of the weaving end-effector. In general, the various components are exploded to understand its component parts.

The diverse components and parts of each end-effector were customized for their use in the system. In the case of the weaving tool, the planetary gears and the motors create the necessary mechanics to weave and structure the composite strand. In the process of creating an end-effector, it is essential to understand how all the previous studies come together to form an automated proposal and a robotic tool.

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Planetary Gears

Wiper Motor

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Weaving end-effector exploded details Figures top and opposite: 3D digital model showing the various components and mechanisms of the weaving end-effector. In general, the various components are exploded to understand its component parts..

The diverse components and parts of each end-effector were customized for their use in the system. I. Robot Mount Plate II. End Effector Power Supply III. Material Input: Straight Wires IV. Wiper Motor V. Frame VI. Planetary Gears VII. Planet Pinion Carrier VIII. Sun Gear Output 6x IX. Planet Pinion Output 6x6 X. Integral Gear XI. Material Output: Weaver Wires

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In terms of programmability of the end effector we link the ability to achieve different weaved patterns with a structural evaluation process which is based on structural analysis algorithms for linear elastic systems (millipede plugin for grasshopper). The differentiation of the thickness of each strand in the cross section can be translated through differentiating the rotation speed of the end effector. At the end we show an example of a simple shell where each main strand is projected straight in a planar view and the weaving pattern is related to the logic that was described before.

left: structural evaluation and basic extracted parameters of different shells

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programmability of the weaving end effector and resulting patterns based on different parameters

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weaving pattern of strands that compose the shell based on structural evaluation

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The Gripping End-Effector Chapter 3.3.2

Global Transformation Figure: The robotic arm and end-effector during the final testing of the material transformation process.

The gripping end-effector contributes to the conversation outlined initially for the system's overall transformation and formation. In many respects, the gripper is a study of current available grippers on the market, yet has been customized to operate intelligently in this particular system. The gripper is controlled by a linear actuator and an arduino micro-controller which can begin to feedback information to the robotic choreography that will eventually manipulate all strands to give shape to an architectural construct.

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Initial Gripper Versions, Mechanically Operated

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Mechanical Gripper v.1

Mechanical Gripper v.2

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Mechanical Gripper V.1

Mechanical Grippers Figures top and opposite: 3D digital model showing the various components and mechanisms of the mechanical grippers. V2 grippers were built as well to test at Robofold. These were designed to test the last version..

The mechanical grippers functioned principally hand-operated. Though robotic intelligence was a part of the project, it was not fully developed at this point and so the grippers were designed to first be operated manually. In the case of the mechanical grippers, the design was based on tube clamps, mechanisms which could similarly grasp the strands and manipulate them into place.

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Mechanical Gripper V.2

Models of Mechanical Grippers V.2

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Anchor Points and the Fabrication Gripper attached to robot

Anchor Points and the Fabrication Gripper Figures top and opposite: 3D digital model showing and the robotic tests done with the anchor point gripper.

The robotic fabrication gripper was used during all of the tests to anchor the ends of the strands to the robotic arms. In many regards, it was an approximation of what the anchor points of the system would look like and how they would hold the strands together.

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Fabrication Tests with the anchoring points and plates.

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Figures top and opposite: Component parts of the anchor point gripper and plates: I. ABB Metallic Plate (6th Axis) II. Wood MDF Plate (12mm) III. Metal Anchor Plate (Grip) IV. 12cm Grip Perforated Plates V. Bolts 6m Metallic VI. Wood Anchor End Plates VII. End Plate 70 Wire Base.

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Fabrication Gripper

Each of the plates as they evolved were meant to hold and anchor a different amount of wires. In this particular case, there were 60 wires attached to the plate yet non reinforced with the fiberglass core. This is the end-plate for the four column test.

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Render view of fabrication gripper

Mechanical Gripper v.2 Figures top and opposite: 3D digital model showing the gripper mounted on the robot. Images of end-effector mounted on the robotic arm. Diagrams of the two types of grippers.

The mechanical gripper was meant to operated manually during the testing process. These two types of grippers were modeled after tube clamps and meant to transform the material by grasping them similarly to a tube. In many regards the evolution of material led to the evolution of the design of all end-effectors, particularly the gripper, as aspects of the system not only had to become automated, but had to eventually return some kind of feedback to the system.

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Gripper mounted on the robotic arm for testing.

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Robotic Tool Automation Gripper V.3

Robotic arm technology brings with it the ability, and often requirement, of automating a process. or system. In regards to the system, automation of the gripper dealt principally with the notion of returning information with which to inform the robotic choreography. As is essential in any system, the robotic arm requires an input at every instance of position, direction and payload. It must know where and what it is manipulating, for how long and how much. In the case of the gripper's subsequent test phase, the mechanics were coupled with an arduino micro-controller and a push-button to inform its movement and action in space at any particular moment. Though the micro-controllers can be coupled directly and be informed at every instance by the robotic program.; the decision still remained in the hands of the user.

Fourth version of the gripper built and developed with a linear actuator, arduino micro-controller and pushbutton.

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Automation Arduino Micro-controller Frames: Stills of arduino micro-controller trials. The linear actuator is told to run 4 seconds clockwise and 4 anti-clockwise in order to open and close the gripper.

Automating the gripper meant adding specific instruction to the operation of the tool itself. In this particular case part of the code made use of the controllers of 12V motors to operated the linear actuator and program its behavior. For example: void loop() { buttonState = digitalRead(button); if(reverse == false && buttonState == HIGH){ Serial.println("clockwise rotation (pin04)"); //run the Motor clockwise for X amount of time, then stop for Y time digitalWrite(clockwise, HIGH); delay(10000); digitalWrite(clockwise, LOW); delay(2000); reverse = true;

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Robotic test with actuated gripper

Robotic Test with Gripper Frames of robotic tests with the automated gripper at the end of the robot. Opening and closing coordination.

The automated gripper was tested on the robotic arm to show the specific commands that a robotic arm with this end-effector would perform in choreography. The robot gripper opened and closed on the robotic arm to prove the construction of the overall system's automated processes. In this particular occasion, the robotic arm encountered a few issues with the external hardware attached, this had to be isolated from the magnetic fields on the robotic axes in order to work properly. Designing automated end-effectors is not a process as straight-forward as it would seem.

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Transformation end-effector detail. Figures top and opposite: 3D digital model showing the various components and mechanisms of the gripping end-effector. In general, the various components are exploded to understand component parts.

The diverse components and parts of each end-effector were customized for their use in the system. In the case of the gripping tool, the clamps and the linear actuator together create the necessary mechanics to move and transform the composite strand. In the process of creating an end-effector, it is essential to understand how all the previous studies come together to form an automated proposal and a robotic tool.

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Arduino Microcontroller

2 Channel Relay

12V Linear Actuator

Push Button

Transformation end-effector exploded details Figures top and opposite: 3D digital model showing the various components and mechanisms of the gripping end-effector. In general, the various components are exploded to understand its component parts.

The diverse components and parts of each end-effector were customized for their use in the system. Instructions: I. Arduino Microcontroller II. 2 Channel Relay Core: III. Linear Actuator 12V, 10cm IV. Metal 3 Plate Structure V. Metal Support Bars VI. Robot Mount Plate Gripper Base: VII. Pivot Connections VIII. Thrust Bearings at all connections IX. Linear Actuator Anchor and Front Gripper: X. 30cm Jaw Opening XI. 10cm Close Diameter XII. Rubber Edge

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The Heating End-Effector Chapter 3.3.3 Local Transformation Figure: The robotic arm and end-effector during the initial testing with the halogen heater tool.

The third aspect of the process that was chosen for customization was the setting aspect of the material. For this process a series of heating techniques were applied until the design of the final end-effector was chosen. In this particular case, the heater is a halogen lamp based tool that allows the material formation process and time to minimize and effectively set the overall formation of the structure generated.

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The process of heating is the last and final stage of robotic fabrication that freezes the structure in space. Once subjecting the woven out material to deformation , it needs to be heated uniformly throughout so as to avoid over and under heated areas which may lead to the failure of the structure. Therefore, the criteria of uniform heating becomes structurally essential and hence, it was important to choose the appropriate technique that would melt the nylon with the right temperature and stabilise the structure within the required time period. For this process we tried five different methods of heating and mapped the time and temperature taken by each to melt the material system. 1 - Heat Gun 2 - Boiling Water 3 - Electricity 4 - Induction Heating 5 - Halogen Heater

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+ Melts Nylon. - Time of heating 180sec.

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+ Hardens nylon, as nylon absorbs mois ture. - Does not melt nylon.

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+ Conducts heat quicly through nylon and spring steel. - Breaks spring steel, decarbonises it and reduces its strucutral capacity.

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+ Melts nylon within 120 sec. - Heat generated is high and needs a medium to dessipate the same.

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+ Melts various thickness of nylon with 60 sec.

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Heating end-effector detail. Figures top and opposite: 3D digital model showing the various components and mechanisms of the heating end-effector. In general, the various components are exploded to understand component parts.

The diverse components and parts of each end-effector were customized for their use in the system. In the case of the heating tool, the various studies in heating components that were analyzed before allowed for the final outcome and the best system to heat and set the material. In the process of creating an endeffector, it is essential to understand how all the previous studies come together to form an automated proposal and a robotic tool.

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Halogen Coil

Metal Grill

Power Supply

Heating end-effector exploded details Figures top and opposite: 3D digital model showing the various components and mechanisms of the heating end-effector. In general, the various components are exploded to understand its parts.

The diverse components and parts of each end-effector were customized for their use in the system. I. Robot Mount Plate II. Grooved Heat Plate Casing III. Aluminum Plate IV. Power Supply and Connection V. Heater Plates and Coils VI. Electrical Connections to Coil Heads VII. Operation Setting Panel VIII. Metal Grill

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The thermal camera captures highlight the temperature at crucial points of the 2metre tall prototype while it was being heated. The temperatures recorded were during the time interval of 20 - 25 minutes post the starting time.

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Robotic Fabrication Cell Chapter 3.4

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234 kUKA Cell for Palletizing Robots

Cell Production USA

Kuka Tessla Robotic Line

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Robotic Cell for Rail Robots

Robotic Arm Fabrication: Designing the Cell Case Studies

Robotic arms are essential aspects in the design of the workspace of a robotic cell. As these cannot simply exist in open space without some kind of limitation, the cell becomes an essential element of its use. For the system, a cell was designed to incorporate all the necessary aspects of deployment and use for the robotic arm fabrication technique in mind. A robotic cell's specifications rely on the needs of the system itself, the requirements for the architecture's construction and material deployment. With optimal process and reliability in mind, the system offers the maximum flexibility for the specific tasks required of the robotic arms. The cell is an intelligent stand-alone solution that meets the most demanding aspects of our system's requirements and can be further customized to include further developments of the design parameters and architectural proposals. As several of the case studies shown, the cell has many diverse arrangements intended to facilitate the purpose the robotic arm serves. In the case of our proposed system, the cell must not only accommodate the operational space of a static robotic arm, but of its extended operational space on rails.

Images: 1. Kuka Cell. www.acieta. com 2. Kuka Cell: www. directindustry.com 3. Palletizing Cell: http:// vimeo.com/112181328 4. Robotic Cell Construction Company USA.: www. qcomptech.com 5. Tessla Kukas: www. crossfire.nu/user/2323293/ deactivated5681

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ABB IRB 6640 Choosing a Robotic Arm for the System Figures top: Image of chosen ABB for the system. Opposite: Details of the robotic arm and rails in the cell.

The IRB 6640 is a strong robot with application in numerous applications. It is an update of the previous generations of IRB 6000 robots. The recent updates in the upper arm extender and the different wrist modules allow for further customization of each process, "as the robot can bend fully backwards, the working range is greatly extended allowing it to fit well into dense production lines". The typical application areas are material handling, machcine tending and spot welding. It is a robot built for heavy duty work with extreme precision. The robot can be easily mounted on rails and form part of a system whose complexity requires extreme flexibility.

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170 degree rotation at base and 235kg of payload

2.55-2.75m in Height and 3.10m reach

40 to 50cm off the base of the cell as mounted rails

3rd to 6th Axis Extension is 2.75m

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Understanding Robotic Limitations Designing the Cell Figures top and opposite: 3D digital model and turntable analysis of the robotic arm.

Understanding the limitation of the robotic arm is essential to design the robotic cell. In the case of this particular ABB, the reach is magnified by the robotic arm's added length on the part of the rails. The system becomes even more customized for the construction of its architecture. To design the space of occupation of a robotic arm, one must first determine the orientation in which it deploys. In this particular case, the robot is working within a rectangularly shaped space.

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Robotic cell layout and overall shape and parameters

Off-site production Figures top and opposite: 3D digital model of the final cell model. Off-site production was chosen to minimize the unexpected and maximize the ability of producing with the "lights-off".

The design of the cell and its overall parameters once specified was developed once more to take into account all of the aspects proposed for the design process. In this particular case, after the studies of gantries and robotic movement were performed, the cell's final output was finalized as a rectangular operation space with mounted rail robots. The decision to make the cell static and within an industrial work-space is associated mainly with the fact that robotic arm technology is hard to operate out in the open. Off-site production allows the process to have complete control and to generate the architecture in one place. As the shells are lightweight, their shipment to site is not difficult or too costly when compared to on-site production.

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I Extension in X rails: The robotic arm deployment is amplified by the extension of the rails.

II ABB IRB 6640 High Payload: The chosen robotic arm for the system.

III Extension in Y Rails: The extension along the length of the cell. This can be further customized to include the optimization of the material itself. Should the length of the strand lengthen.

IV Rail Supports: Sustain the platform and rails above the cell's floor.

V ABB Controllers: The operation hardware of the robotic arms included, these are usually kept outside of the cell.

VI Perforated Platform: The platform itself considers the anchor points of the system so they may be placed temporarily into a specific point in space.

VII Horizontal Rail Supports: These allow for the extension and expansion of the rails themselves and take into account the added mobility of the rails.

VIII Robotic Cell Guard Rails: These keep personel outside of the cell during operation.

IX Robotic Cell Offset Platform: Base of the platform and cell itself. Offset off ground.

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Three Phase Process

Weaving Process The first phase of production is the generation of material, in this particular instance of production, only two robots are in operation as they travel along the length of the cell to deposit the material strands. This process makes full use of the space of operation, the deployment of the robotic arm along the length is determined by the length of the material strand itself.

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Transformation Process

Heating Process

During the transformation phase of the process there may be four or more robotic arms in play. The control points themselves require at least two robotic arms on each side of the cell and at least 2 or more potentially added on the other axes to operate on control points. In this particular case, only four robotic arms were used to simulated the construction method.

Once again only two robotic arms are used to operated the heating process. As these must also thravel along the length of the shell in order to reach as much material as possible. Due to the constraints of the overall system, it is possible that this process requires as well manual intervention, as the robotic arms themselves cannot fully reach all points of an already popped-up structure.

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Staubli robotic arm, Maya inverse Kinematic Rig.

MAYA's Inverse Kinematics Robotic Control and Simulation Figures top and opposite: 3D digital model and IK system showing the movement of a robotic arm in space. Choreography intentionally testing the arm's limitations.

The study of robotic control took place on many platforms, yet the most worked out aspects of the cell and its construction were studied with Maya's Inverse Kinematic Model. A rig with all the specifications of the robotic arm limits and specifications was used to model and simulated the system. In this particular test, the robotic arm was mounted on a rail and set to perform a series of movements to test its limits within the application. For the cell, a similar process was done to test the overall choreography of building one proposed shell.

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Weaving Process Figures top and opposite: 3D digital model showing the choreography of the weaving process.

Simulation of the weaving process was done using the Maya IK model and made to test all of the specifics of building one of the prototypes proposed for the architecture. In this particular case the robotic arms are seen coming together to lay down the material strands and propose the initial choreography of generating the material strand along the length of the robotic cell.

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Transformation Process Figures top and opposite: 3D digital model showing the choreography of the pop-up process.

Simulation of the transformation process was not only a matter of trial and error, but of finding the adequate software to showcase this effectively. By means of blend-shapes and deformers, the pushing process was simulated to illustrate how the pop-up process of the architecture could be effectively shown. In many regards, this simulation illustrated, from all the different views taken, how choreography, robotic tools and the cell all contribute to the formation and creation of one of the architectural constructs proposed.

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Heating Process Fig.ures top and opposite: 3D digital model showing the choreography of the heating process.

The final phase of the simulation dealt with the last process of the system: material setting. The choreography clearly shows how the robotic arm's deploy along the length of the platform to heat as much of the structure into its final configuration, solidifying the material process as the halogen heater is moved along the strand. In this particular simulation, the notion of how many robotic arms would be used for each process was essential to understand how the cell could be further evolved as the process continued to change.

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Design Process Chapter 004

0. Introduction and Case Studies 1. Initial Studies 2. Empirical Approach 3. Numerical Approach 4. Geometrical Approach

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The fact that our research relies on an industrial robotic process and a uniquely engineered composite material made it necessary to develop a design tool that could be customized according to the needs of the fabrication process. Through the observation of the material behavior the research focused on active bending structures that perform in a similar manner. Active bending structures are unique in their performance and therefore can not be predicted without the use of a form finding process. This process needs to be iterated and compared through a series of digital and physical prototypes. Moreover, in the development of the design methodology, essential role had the robotic armsâ&#x20AC;&#x2122; constraints and possibilities, which gave feedback to it and indicated whether certain design rules for applications were feasible or not.

Left: Geometrically defined structural network. Right: Physical model of spatial deployment. Empirical approach of the design process.

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The form finding process of the Mannheim Pavilion involves a hanging chain model. In general these models are effective in creating pure tension shapes, that when inverted, create pure compression shell results. The curvature is a result of a series of hanging chain models that have been translated into an active bending model. This can happen because of the similarity of the two curves, the catenary and the elastica one, when the end points final distance does not pass the limit of the 1/3 of the initial distance. Based on this models Frei Otto achieved to calculate and build a complex gridshell structure of 60m maximum span by linear- flat timber beams of 5cm thickness, after pushing the anchor point of the shell into the desired position given by the hanging model.

Project: Multihalle Place: Mannheimer Herzogenriedpark Year: 1973-1975 Material: wooden slats, PolyesterPVC Membrane Form-finding: physical models, firce density Architect: Frei Otto, Ewald Bubner, Carlfried Mutchler,Joachim and Winfried Langner

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Active-Bending Structures Reference projects

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Active-bending structures are structural systems that include curved beam or shell elements which base their geometry on the elastic deformation from an initially straight or planar configuration.1 The generation of form is directly influenced by the characteristics of the material. Form-finding and the general design process have to satisfy both mechanical and architectural specifications. Taking into account the structural behaviour or our composite material, which performs as an active bending structure, several case studies were analyzed in order to understand better how the formulation of the design rules occurs.

ACTIVE BENDING BEHAVIOUR

Water and Wind Cafe Vo Trong Nghia.Binh Duong, Vietman. 2008.

Windshape nArchitects & SCAD, 2006

1. Julian Lienhard, Bending -Active Structures, Form-Finding strategies using elastic deformation in static and kinematic systems and the structural potentials therein (Universitat Stuttgart Forschungsberichte)

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Structure study - Primary and secondary skeleton

Surface study - Thermoformed plastic skin

Bending - active structures are more an approach than a structural category.

In the numerical approach, digital simulation was used as a tool of exploration of a wide solution space. A physics engine facilitated the approximation of the material behaviour digitally and the generation of a vast number of iterations led to a better understanding of a creative use of the limitations of bending-active structures.

‘‘Their common denominator is not a circumscribed load bearing behaviour or geometrical definition, but a formation process during which they are elastically bent.’’1 For this reason, in order to generate a design methodology, several distinct approaches were realized. Those were strongly connected on a conceptual level and each one provided feedback for the rest. THE APPROACHES More specifically, the design system was generated from three different perspectives : empirically, numerically and geometrically. In the first case, material behaviour and limitations were tested through physical models. This was an essential phase where design intuition was developed.

Finally, the experience and knowledge gained from the aforementioned approaches were a factor of high importance in the development of the third, geometrical approach. In this case, a procedural design strategy was generated, where the actual physical bending behaviour of the structure was approximated, based on observations made during the previous experimentation.

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DIGITAL SIMULATIONS PHYSICS ENGINE

PHYSICAL MODELS MATERIAL FORMATION

FORM - FINDING GEOMETRICAL DEFINITION

Different Design Techniques Feedback on the process

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Empirical Approach Chapter 4.3

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In the earlier attempts to form a design process, several stategies that through trial and error formed the current design methodology were investigated. It is essential to point out the main goals of this research so as to make the concepts behind the current process more easily understood and also demonstrate the continuity of the research analysis. More specifically, through an empirical approach, a series of physical models were generated, based on design intuition and observations on the material behaviour. Starting from simple setups, the fundamental structural concept of bending active structures were studied, while the initial design concepts were being generated. Essential observations where made during this stage of the research, such as the importance of the network in opposition to the structural behaviour of single elements. In this phase, the use of experimental form-finding methods led to the definition of the material constraints and liberations, as well as to the perception of the design potentials of the system. The latter formed the design tools that were used in the later research, in all the other design approaches.

Left: Physical wire model Network study Scale 1:25

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Two direction braid

Two direction weave

Clockwise movement Counter-clockwise movement

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One direction twist

Two direction weave

Early Design Process Weaving Patterns The main concern about this early design process was the evaluation of the behaviour of the wires, depending on the configuration of the weaving pattern. This experimentation concerned the micro scale of the material setup.

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Weaving Patterns Physical models

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Early Design Process Network Patterns The main concern about this early design process was the evaluation of the behaviour of the wires when they are interconnected in a network. Different constraint patterns generated vast diversification of the outcome, while the initial setup remained the same.

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Network Patterns Physical models

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TWISTING

VERTICAL DEFORMATION

Wire Network Deformation Studies Each network of wires was imposed to several deformation studies. The main observations made were that the number of constraints and their proximity defines in a big extension the level of control and the resistance to the applied force.

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Based on the previous physical experiments, the observations made concerning the material behaviour of the wires led to generation of a design concept based on pop-up structures. More specifically, the reaction of the wires when force was applied and their tendency to maintain a certain curvature, promoted the idea of the utilization of this inherent material characteristic in favor of the fabrication process. For this reason, the concept of laying the material flat on the ground in a first phase, creating the constraints and generating the network, and actuating the system through control end-points, was the evolution of the design methodology. Moreover, this initial design approach started to form the frame for the robotic function and shell.

Left: Physical model 3dimensional network Right: Physical model Flat 2dimensional deployment

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Pop-up Concept Flat network generation

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BY LATERAL ANCHOR POINTS linear spaces

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Anchor point Type 1 - Arch

Neighbouring wires connection Structural linear elements

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Anchor point Type 2 Transition from top to bottom

Crossing connection Space creation

In this physical experimentations, the first attempts for space creation were made. Differentiation in achor points and type of connectivity (cross or tangential) dictated the geometrical and structural outcome.

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Taking the previous experimentations one step forward, a series of physical models was created in order to evaluate the assumption that space creation highly depends on the position of the anchor points of the overall structural network. Indeed, maintaining the same initial setup and altering only the location of the mid-anchor points, the generated space could vary in proportions and interconnectivity.

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This observation gave valid to the idea that the unpredictability of active bending structures can be minimized when the independent single elements are joined together in a network and the latter is being perceived as a bigger malleable entity.

Left: Detail of physical model Tngential and cross connections Right: Physical models Same initial setup Differentiation in spatial outcome

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Spatial Deployment Space differentiation In these experiments, the topology of the initial setup remains stable, except from the position of the middle anchor points. This little change generates different spatial qualities and can provide control over the design according to specific intentions concerning the connectivity of the interior spaces.

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TWO CONNECTED SPACES by lateral and central connectivity

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ONE LINEAR SPACE maximum connectivity

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Middle anchor points Transition from top to bottom

In this physical experimentations, the possibility for space differentiation was manifested.

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Numerical Approach Chapter 4.4

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In a numerical approach of the design process, the material characteristics of the wires were given as parameters to a physics engine, in an attempt to simulate digitally their physical behaviour. The main goal of this experimentation was the exploration of a wide range of network possibilities and their geometrical outcomes after their actuation and deformation. Continuous calibration of the digital parameters was realized, through the evaluation of the digital outcome ,in comparison to its physical similar result. After the right values were assigned to the physics engine, a variety of constraints, network possibilities and actuation scenarios were tested. This design approach had a satisfying level of validity and accuracy, nevertheless it left very little possibility for experimentation and control over the design. Moreover, while the digital simulation of the wire networks was resembled a lot their actual material behaviour, there was no possibility of inputting additional information, such as material behaviour in a micro scale - in this case the melting local deformation of the nylon.

Left: Final wire network configuration

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In a defined grid, six strands are laid flat and straight on the ground. The middle anchor points are static and fixed, while the ends are getting actuated. The strands are interconnected in a network, each time with a different pattern. This configuration defines in a very big extend the final geometrical outcome.

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As the end points get actuated in the simulation, the connected points are getting closer through the application of a particle-spring system. In that way, they are interlocking and becoming constraints to the movement of the networked system. The final bent flat configuration becomes popped-up by giving a defined angle to the end anchor points. The overall structure remains in equilibrium after the forces and the constraints cancel each other out.

Stage 1: The material is laid flat on the ground. The middle anchor points get fixed. Stage 2: The end points are being moved and connected. Stage 3: The bent structure gets popped-up. Stage 4: The system reaches a point of equilibrium.

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Digital Simulation Bending deformation

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Physics Simulation Four-wire network

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grid 30x50 middle anchor points: 5 connections: 6 symmetry: x/y axis force between connections: -100 movement: +/-7 on x, to the inner points on y

grid 30x50 middle anchor points: 5 connections: 6 symmetry: x/y axis force between connections: -100 movement: +/-7 on x, to the center on y

grid 30x50 middle anchor points: 5 connections: 6 symmetry: no force between connections: -100 movement: +/-9

Physics Simulation Six-wire network

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In a continuation of the initial digital physics simulations, spatial parameters were added to the initial setup. Through observation of the materialâ&#x20AC;&#x2122;s capabilities, six spatial primitives were defined. The latter responded to different spatial conditions and more specifically, to different planes of reference. Through a combination of those, a complex result was achieved.

308 ROBOTâ&#x20AC;&#x2122;S LIMITATIONS / CAPACITIES

The definition of the initial primitive plane conditions depended on the capabilities and limitations of the robotic arm. The actuation of the strands was considered to happen within the range of movement and rotation of the robotic arm.

SPATIAL CONDITIONS

The final geometrical output depends on the possibilities and the range of movement of the industrial robotic arm, on the initial setup and spatial conditions and on the design intention, which defines the combination of spatial primitives. COMBINATIONS

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Spatial Conditions Diagrammatic sections

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Simulated Iterations Combinations The space differentiation is an immediate result of the initial planes of reference, according to which the network of wires gets actuated.

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Diagrammatic sections

TYPE A One plane of reference

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ALTERED FLEXIBILITY ZONES

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Diagrammatic sections

TYPE B One plane of reference

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ALTERED FLEXIBILITY ZONES

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Diagrammatic sections

TYPE C Two planes of reference

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ALTERED FLEXIBILITY ZONES

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ALTERED FLEXIBILITY ZONES

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ALTERED FLEXIBILITY ZONES

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Diagrammatic sections

TYPE F One plane of reference

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ALTERED FLEXIBILITY ZONES

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Geometrical Approach Chapter 4.5

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Having in mind the knowledge and experience gained from the empirical and numerical design methodologies, a different approach was attempted, combining the latterâ&#x20AC;&#x2122;s characteristics. In this geometrical design technique, an analytical strategy was followed. Through procedural modeling, approximations of physical experiments were generated. Nevertheless, the accuracy of these approximations was of a high level, due to the fact that the initial input was based on the intuition gained, the observations from the digital simulations, as well as due to the use of mathematical equations on which the physics simulations are based on. From an overall perspective, this approach was the most efficient of all, as it combined the advantages of the earlier research methodologies, while introducing the element of the design initiative.

Left: Geometrically generated primary and secondary structure.

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TANGENTIAL MID ANCHOR POINTS

VERTICAL END ANCHOR POINTS

Network Generation Constraints Vs. Deformation The design rules inherited by the previous design approaches indicate that the most essential parameters in all experiments are the generation of the initial setup and the deformation process. In the initial setup, tangential connections joint he strands and create stronger structural networks, while cross connections differentiate the space that is created. Similarly, tangential anchor points create transitions from top to ground, and vertical ones create arches. These are the main design tools that the created system provides and through those the design and the creation of space can be programmed.

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Iteration of primary and secondary structure. Level of complexity: Medium Space of Occupation: 1 Density of Secondary Structure: High Perforation: Medium

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Initial setup Footprint definition

Plane deformation Space definition

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Geometrical manipulation of deformerâ&#x20AC;&#x2122;s edges

Primary structure generation

Merging of vertices Creation of connections

Secondary structure generation

Geometrical Evolution Form-finding process

Curve extraction Network creation

Surface generation

In the first stage of the geometrical design approach, the basic volume of occupation is being defined, as well as the space separation. Then, with the aid of a low resolution control polygons the main curves of the structure are extracted. The latter consist of an approximation but are however based on physical and numerical simulation. From this curves the primary and secondary structures are generated, as well as the thermoformed surface.

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Structure generation through manipulation of a low resolution control polygon. Initial Condition from 2 plane of references.

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CONTROL POLYGON

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grid 12x8m middle anchor points: 10 connections: 15 wires:13 ground points: 6 spaces: 3 initial control polygon: 1

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grid 12x8m middle anchor points: 2 connections: 8 wires:12 ground points: 8 spaces: 2 initial control polygon: 2

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CONTROL POLYGON

vertical cylinder connections: 5 wires: 12 intersections: 1 thickness: 1 control vertices: 48

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vertical cylinder connections: 20 wires: 8 intersections: 2 thickness: 2 control vertices: 56

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vertical cylinder connections: 20 wires: 8 intersections: 0 thickness: 3 control vertices: 56

vertical cylinder connections: 20 wires: 10 intersections: 0 thickness: 2 control vertices: 70

vertical cylinder connections: 30 wires: 16 intersections: 0 thickness: 2 control vertices: 112

vertical cylinder connections: 30 wires: 10 intersections: 3 thickness: 2 control vertices: 70

vertical cylinder connections: 20 wires: 10 intersections: 0 thickness: 2 control vertices: 40

vertical cylinder connections: 15 wires: 10 intersections: 3 thickness: 2 control vertices: 70

vertical cylinder connections: 20 wires: 10 intersections: 7 thickness: 2 control vertices: 70

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The low resolution control polygons are subjected to five different circular array conditions. The iterations generated are then transformed depending on the spatial requirements based on two rules: Rule A : Merging of vertices - Generation of primary skeletal lines. Rule B : Merging the adjacent edges - to generate the required surfaces.

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Transformations: Rule A Merging of vertices

Rule B

Merging of edges

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primitives merged edges faces edges verts curves

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primitives merged verts faces edges verts curves

primitives merged edges faces edges verts curves

primitives merged verts faces edges verts curves

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primitives merged verts faces edges verts curves

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Design Process: Linear Arrays

The low resolution control polygons are subjected to five different linear array conditions. The iterations generated are then transformed depending on the spatial requirements based on two rules: Rule A : Merging of vertices - Generation of primary skeletal lines. Rule B : Merging the adjacent edges - to generate the required surfaces.

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Transformations: Rule A Merging of vertices

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Merging of edges

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primitives merged verts faces edges verts curves

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Skin & Secondary Structure Chapter 3.2

The following studies focus on the generation of skin and secondary structure. It explains the materials used for surfacing and secondary structure and the rules of generation of the same.

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Thermoformed Surface Studies Iteration 1

Iteration 2

Iteration 3

Single space

Double Space

Triple Space

The iterations above show three primary structures surfaced according to the available usage space of the frame namely single, double and triple spaces. These structures apart from the spatial requirements can also be surfaced based on function and partition, thus making them customizable. customisable.

Secondary Structure Studies Iteration 1

Iteration 2

Iteration 3

Density Differentiation

Intersection Differentiation

Perforation Differentiation

The secondary structure is made up of tensioned wires. Apart from the structural requirements, the secondary structure can be also be reinforced into the primary structure on the logics of density, intersection and perforation.

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SURFACE Shrink Wrap Plastic

SECONDARY STRUCTURE Tensioned Wires

PRIMARY STRUCTURE Exploded View of Structural Layers

Spring Steel, Fiber Fibre Glass, Nylon Coating

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Physical Model Primary and secondary skeleton This 1:25 model investigates the combination of primary and secondary skeleton. The primary structure consists of the developed composite material (nylon/spring steel/fiber glass), while the secondary is consisted by tensioned cables.

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Physical Models Surface studies In these physical models, plastic film was thermoformed over the wire primary structure. Different surface patterns were tested, in order to investigate issues of denstity and perforation.

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Surface - Thermoforming Shrink Wrap Vs Petg Plastic Comparison Chapter 5.1 Shrink Wrap Time : Temperature :

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Final Architectural Proposal Prototype Perspective Views

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3D Print Models Primary and secondary skeleton

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3D Model Detail One Space Prototype

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3D Model Detail Three Space Prototype

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ACKNOWLEDGEMENTS STUDIO MASTERS Theodore Spyropoulos(Director) \ Patrik Schumacher(Founder) Rob Stuart Smith \ Shajay Bhooshan TUTORS Oliviu Lugojan - Ghenciu \ Apostolos Despoditis TECHNICAL CONSULTANTS Gregory Epps \ Emma Epps Florent Michel \ Vincent STRUCTURAL CONSULTANTS AKT II \ Albert Williamson Taylor \ Ed Mosley Frei Otto STUDIO SUPPORT Alicia Nahmad \ Vishu Bhooshan Asborn Sondergaard \ Alexander Dubor SPECIAL THANKS Michail Desyllas \ Jose Pareja Henry Louth \ Octavian G \Angel Tenorio Phase 1 Aditya Bhosle \ Ramzi Omar \ Andreas Y K Marialena Bali