M.Arch_Design for Manufacture_Term 02 by Harsh Shah

Digital-Physical Workshop

MODEL-MAKE-MEASURE BARC0173 - SKILLS MODULE

DATE

Oct 2021 to Jan 2022 TYPE

Individual Work COURSE

Skills Module PROGRAMME

M.Arch - Design for Manufacture MENTORS

Peter Scully Donat Fatet Hamish Veitch Sienna Griffin-Shaw Robin Mather

Samuel Turner-Baldwin Melis Van Den Berg Ben Lee William Victor Camelleri Arthur Prior

//Joinery & Connections

//Digital Fabrication

//Parametric Design

CONTRIBUTION

Solid Modelling - Autodesk Fusion 360 Surface Modelling - Mcneel Rhino Parametric Modelling - Mcneel Grasshopper Additive Manufacture - Clay 3D Printing Subtractive Manufacture - CNC Milling & Casting

//Material Behaviour

//Machines & Tools

To develop the skill of selecting appropriate tools for model, analysis, machine control and visual communication. In design for manufacture, the emphasis is on a fluid flow of data between design representation and fabrication information. - Chris Leung, UCL Bartlett.

2021/22

STUDENT NO. 20111292

THE DESIGN PROCESS FUSION 360 - solid modelling

3mm laser cut triangles

Ø2.9

Ø3.2 B

150

C bigger hole joint - brass threaded insert 4mm wide x 6mm deep with button hex head drive screw

small hole joint - 3mm wide x 5mm deep insert

Tetrahelix - fabricated & prototyped precedents

Understanding tetrahelix structures, their geometry, parameters and constraints and to use the in-built design-to-manufacture components of Fusion 360 to develop a process from 2d sketch to 3d prototyping. To also detail and model the connections for assembly. E

01 Fusion360 drawing templates to communicate the design intent. Dept.

Technical reference

02 Aid of sketch grid and construction lines to define constraints. 03 Modifications by the adaptability feature of the constraints.

Approved by

Document type

Document status

Title

DWG No.

TetraHelix

04 To nest the multiple 2D geometries using Arrange command. 05 Physical prototyping of the panels using Laser Cutting

Created by

Harsh Manish Shah 14-11-2021

F Rev.

Date of issue

Sheet

1/1

TRUNCATED NODE DEVELOPMENT FUSION 360 - joinery detailing

01 Incorporated drawing specific node requirements as per the available physical fixtures.

02 Use of stitched surfaces, construction planes and extrusions to generate form. 1

04 3D printing and physical testing of the developed node joinery assembly configurations.

03 Defining the node depths and obstructions as per physical-digital processes. D

Dept.

Technical reference

Created b

Harsh M

Document

Title

Trun

Use of the history feature in Fusion360 helps in parametric modelling and design of the modules and making revisions.

TETRAHELIX ASSEMBLY SETUP FUSION 360 - assembly configuration

physical ‘making’ of the assemblies 1

A digital ‘sequencing’ of the assemblies

A (1:2) C

B (1:3) digital ‘modelling’ of the assemblies

node joinery

RE-DESIGN PROCESS

FUSION 360 - generative design

7 8 manufacturing intent - sheet bending

Process - curve bending to hold the primary structural rods

Establishing a primary structural The panels become the secondary frame of tubular metal elements. structural elements as facade or so.A

B B

Applying generative design on the nodes for optimising scalability.

Different flange and bend options as per the angles at joints

Single panel rotated and repositioned at the locations. E

Obstacle geometry Starting shape Preserve geometry

A (1:2)

Dept.

conceptual design & modelling

assembly

Novel structural elements design

detailed view Dept.

1. Node geometry development 2. Primary structure construction 3. Secondary detachable panels.

Technical reference

Approved by

Document type

Document status

Title

DWG No.

Harsh Manish Shah 15-11-2021

assembled units

Created by

TetraHelix Structure_new

Rev.

Technical reference

Created by

Approved by

Document type

Document status

Harsh Manish Shah 15-11-2021

generative design TetraHelix Structure_new Title

optimised node

Date of issue

Sheet

1/1

DWG No.

Rev.

Date of issue

THE DESIGN PROCESS

RHINO - surface modelling

Flat Head Housing Flat Head Housing

48.00

8.00

12.00

5.00

1.00

1.00 1.00

Housing Ring

1.00

Nylon Washer

12.00

0.50

Glass

0.50

Glass

23.00

0.50

Nylon Bush

0.50

Nylon Washer Nylon Bush

23.00 8.00

48.00

5.00

Nylon Washer

SS WasherSS Washer Spider legSpider leg

SS Washer

18.00

29.00

40.00

13.50

M18 Threaded Bar

13.50

M18 Threaded Bar

5.00

M18 Nut

2.50

37.25

5.00

2.50

M18 Nut

Spider Fitting M18 Routel 1:2

3D Modelling a spider fitting routel in Rhino The aim is to model a set of fabrication components for a spider fitting routel from a dimensioned drawing and exploring the surface modelling features of NURBS based designing software Rhino - working with layers, isometric drawings and presentations.

01 Understanding a modelled drawing - spider fitting M18 Routel 1:2 02 Details of the fabrication components through 3D isometries. 03 2D front and right modelling views to aid the design process. 04 Demonstration of working with layers to understand wireframes.

54 88.00

RHINO - surface modelling

567.60 739.60

SECTION SCALE 1:4

31.15

3.00

50.00 88.00

3.00

01 Process of modelling the arms and its joinery to the central part.

31.15

567.60 739.60

54.46

88.00

2.00

02 2D orthographic projections of the design with dimensions. 50.00

04 Specific

567.60

define

overall

surface

50.00

SECTION SCALE 1:4

03 Detailed wireframed views to show the internal joints. views

54.46

2.00

To customise the design for a spider fitting as per given physical constraints and parameters and explore frreform modelling and sculpting to detail edges, finishes, chamfers and define joineries of its components.

16 2. 46

3D Modelling a customised spider fitting.

326.80

88.00

finishes.

ISOMETRIC VIEW

739.60

SCALE 1:4

DETAIL VIEWS 16 2. 46

SECTION

PLAN

ISOMETRIC VIEW

SCALE 1:4

16 2. 46

88.00

DETAIL VIEWS 50.00

326.80

88.00

FREEFORM MODELLING

50.00

326.80

PLAN SCALE 1:4

02 PLAN SCALE 1:4

FABRICATION MODELLING DIGIFAB - LASER CUTTING

Lasercut fabrication using flat-waffle geometry Using Rhino, to design an architectural element in a small scale and fabricate with the waffle system - generating flat panels with joinery slits, checking fabrication tolerances, material constraints and nesting for optimisation in lasercutting.

01 Final prototype of the vase/lighting fixture which was lasercut. 02 Modelling geometries and contouring as per material thickness. 03 Nesting and arranging forms on the given material sheet sizes. 04 Design and fabrication intent development on Rhino.

PARAMETRIC FORM-FINDING Roof study and manufacturing design

The aim is to build a definition within Grasshopper that defines a roof ‘system’ from a single free-form doubly-curved surface referenced from Rhino covering an area 5m wide x 10m long. The intent was to understand the geometry and model the project by Felix Candela on GH using hypars and thereby understand the variables and parameters involved.

01 02 03 04 05 06

Geometry - parametric variations

The roof system shall incorporate a supporting structure and a secondary layer that forms some form of weatherproofing skin, and it is key to study the manufacturing constraints of the same and how can one rationalise a doubly-curved surface into elements that can be efficiently produced.

ROOF - DIGITAL FABRICATION Grasshopper - parametric design

Construction system 01 - Original formwork design as a steel concrete hybrid

Construction system 02 - independent lightweight metal framework with glass panels

PARAMETRIC FORM-FINDING Roof study and manufacturing design

The first step was to understand the variables involved and develop the geometrical surface. This was followed by two computational approaches to develop fabrication systems.

These systems involved two major structures - internal based on formwork - timber strips and inflated fabric and the external is the concrete shell coating.

01 02 03 04 05 06

ROOF - DIGITAL FABRICATION Grasshopper - parametric design

01 Development of the geometry with above parameters in mind. 02 Isocurves generation as per the spacing between the wooden strips. 03 Dispatching lists to derive alternating points for strips joinery. 04 Offsetting these points to define the wooden strip sizing. 05 Lofting the weave patterns to define the wooden strips geometry 06 Following similar process to develop the alternative strips. 07 Defining curves for the inflated fabrics between the strips. 08 Generating the inflated fabric geometries in between. 09 Geometry with concrete shell, wooden strips and inflated fabric.

Here is the step-by-step development of the computational approach for fabricating the structure from the formwork. The internal structure (the formwork) comprises of the wooden strips and inflated fabrics. The external structure remains the concrete shell.

initial graspings

SUBTRACTIVE MANUFACTURING

BARC0173 - SKILLS MODULE

introduction to ceramic slip-casting & moulding

Design Intent

BEHAVIOUR OF CLAY TO CERAMICS: - Geometry: The shift of draft angles and its relation to clay thickness. - Finish: The variation in surface texture versus the plasticity of the clay. - Distortion: The crack location and behaviour as per openings/texture.

PLASTER CHARACTER AND MOULD PREPARATION : - Viscosity: The consistency of the slip to be tested by eye and feel. - Setting: Plaster lump, setting spread and timing and its nature. - Mixing and pouring: The plaster and water proportions are crucial.

3D SCANNING CALIBRATIONS: - Shrinkage: The role of moisture content and hence volume/measures change. - Positioning: The smooth movement for recording all edges and intricacies. - Post-process: The integral focal point as per geometry for calibration.

The aim was to develop a slip cast terracotta brick that will be able to hold vegetation, a growing medium. With the aid of CNC tooling, how can the tectonics of the given end tools be used to their complete potential?

introduction to CNC machining & 3D scanning

2021/22

3-AXIS CNC TOOLING TECTONICS: - Tool Movement: The axes defines the complex geometry design - GCODE: The movement in space optimises the speed and finish. - End Tools: To define edges, draft angles, slopes and minimum radius.

STUDENT NO. 20111292

precedents

pattern design

DESIGN FOR CASTING F 360 - CAD/CAM & Analysis

given stock solid and brick template

design concept and development

18mm plywood base board (for work plane align)

overall stock solid

proposed CNC cut geometry

Locations for marble balls for two moulds. Connecting locators for other bricks

pattern history development

tool types: roughing/finishing

analysis tests: sectional and draft

12mm dia EM upcut square end mill flat

6mm dia EM upcut square end mill flat

3mm radii BN6 upcut ball nose end mill.

3mm dia 8deg tapered end mill

pattern making

3-AXIS CNC MACHINING F360 - manufacturing & toolpath

01 Adaptive toolpath to avoid toolbreak and maximise toolload.

Machining parameters ROUGH MACHINING

02 Contour toolpath for steepwalls, semi-finish with maximum 03 04 05 06

stepdown of 0.8mm Flat and adaptive - Helical toolpath with ramping angle of 5 degrees and clearance height of 2.5mm Steep & Shallow allows variations in height and valleys in all sloped areas Morph spiral for organic freeforms with stepover variations of 5-8mm Trace toolpath machines steep valleys with maximum slope angle 90 degree

12mm dia upcut square end-mill

FINE MACHINING

12mm dia upcut square end-mill

The intent is to create varying contrasting textures using the maximum potential of the end mills and study the change the behaviour of slipcast at the junctions and valleys of these contour variations.

6mm dia upcut square end-mill

6mm dia upcut ballnose endmill

04 02

8mm dia tapered tool

physical modelling

PLASTER MOULD & SLIPCAST Plasterworks & Ceramics Modelling

aims - observations

01 Negative gaussian curves (steep) has poor finish - needed sanding 02 Selection for brick assembly based on clay base thickness 03 Use of lubricant as separator before pouring plaster was crucial.

04 Level clamping , rounds& acrylic walls aid in moulding/demoulding. 01 Lack of layers of mould soap leads to irregular plaster adherence. 02 Good proportions but quick mixing/pouring led to air bubbles. 03 Plaster and water consistency is important while setting. 04 Toolpath and draft angle mistake led to demoulding issue. 01 Poor fit on mould sections due to separate drying and warping. 02 Peer learning - issues in demoulding due to the design cuts.

03 Plaster behaviour affected the minute textures of the contours. 04 Casting

slip

consistency

mix

and

testing

viscosity.

01 Addition of deflocculant for the clay particles to suspend in water. 02 To check the slip level periodically for even thickness. 03 Time maintenance is key to de-slipping as the thickness varies. 04 Leather hard state of the cast has scope for malleability.

aims - observations - problems - troubleshooting

digital scanning

BRICK-ASSEMBLY & TESTING Bisque firing and 3D Scanning

ASSEMBLY/FIRING/3D SCANNING Fired vs unfired: Change in color and 7-8% shrinkage observed. (measurement and 3D scanning) Precision and Tolerance: Due to the clay slump and the firing, the connection measurement is key.

01 Uniform thickness and drying is observed in forms that work with the clay behaviour - organic and natural gradation in contour. 01 How the parameters of the toolpath can be adapted to achieve complex forms with deep niches? 01 The releasing agent is crucial in the plaster mould development. Also, the demoulding issue depends on draft angle.

The clay thickness is thinner and not uniform along the steep slopes and the textured finishes versus thicker towards the openings and central valley. It however forms a thick edge at the bottom platform. But, the form is poorly stable. The other mould below helps in overall stability due to its strong geometry.

final manufactured brick - inference

01 Effective use of the end mills leads to a fast process and smoother textural finish of the output. 01 Plaster demoulding, the steep-shallow geometric variations and slip formulation - all affects the bone dry clay. 01 The flexibility of the digital GCode generation process in F360 and feedback can lead to efficient milling.

3D scan helps in reverse engineering for the production of multiple moulds, especially accuracy at the joinery for the smooth assembly.

peer learnings - future propositions

initial graspings

ADDITIVE MANUFACTURING BARC0173 - SKILLS MODULE

basic principles of additive manufacturing

control principles of fluid dispensing

programming toolpaths in grasshopper and writing G-Codes

THE FEED SPEED AND EXTRUSION SPEED:

03 A controlled overflow across various points of the

toolpath that impacts the material deposit can help reduce or avoid supports in selected areas.

LIMITATIONS

VARIOUS

3DP

METHODS

01 Overhanging Geometry: How can the ‘pseudoplas-

G-CODE ARTICULATION FOR MATERIAL CONTROL & MOVEMENT:

tic’ parameters of the material be modulated to address these geometries in Clay FDM 3D printing?

05 How can the flow-rate and the extrusion values be modified with the flex-

ibility of parametric modelling and options to modulate in accordance to the design parameters to influence the material and geometry’s stability?

THE ROLE OF SCAFFOLDS AND SUPPORTS:

02 Can the toolpath, 3dp configuration and the ma-

terial parameters be modified to create self-support layers reducing the need of scaffolds?

2021/22

STUDENT NO. 20111292

THE

GEOMETRY

AND

RESOLUTION:

04 How can the potential for geometric and tex-

tural experimentation aid in architectural applications and how can variations be achieved by changing the layer height and stepover factors?

physical manufacturing setup - role of material behaviour

sprint challenge

3DP TOOLPATH STRATEGIES Helical toolpath, lattices and non-planar

TACKLING DESIGN LIMITATIONS OF ADDITIVE MANUFACTURING - Overhangs: Toolpath for overhangs and supports needed using bridge concept. - Toolpath: Playing with printing parameters for varying toolpath for different parts. - Surface Texture: The role of texture in clay behaviour and stepover support.

design parameters

Use of lattice spanning features as reinforcement

Various iterations of geometries were explored considering the overhang (>45 deg) angles. Basic toolpath tests were done varying flow speeds, the following observations: 1. Varying stepover value in accordance to the overhang angle helped in sustaining the form. 2. The collision of the nozzle with the geometry during print needs GCode developments with parametric G91 variations, custom fabricated nozzle or robotic arm 3D printing.

Irregular variation of extrusion deposition along toolpath

The geometry was discretised into parts to order them for print and vary toolpath and speed as per the overhang angles of these parts. Further, temporary supports were considered to act against the force of gravity. However, the form was sliced and turned over to print. These optimisations were considered to modulate the G-code and trials with errors were experimented.

Double thickness-offset toolpath to support complex forms

01 Non-planar toolpath for doubly curved geometry with overhangs . 02 Non-Helical toolpath leads a continuous seam along the geometry 03 Adding texture to the geometry to support the overhang angle. 04 Toolpath collision with the nozzle is another important factor.

A helical toolpath was tested against a conventional one to avoid drops at locations with steep overhang angles. Further, to understand the change in support systems, some surface textures were checked with dispatch lists and weaving points parametrically. Various slicing tools like isocurves, contours, etc were studied to check planar vs non-planar toolpaths for the geometry.

Issues in layer-to-layer adhesion - stepover value change.

physical design tests

3DP FACADE BRICK DESIGN Design concept and design development

INTERIOR PART: 1. Addition of surface texture cools the wind. 2. Varying experiments with changing the deposition volume and extrusion width.

Design Intent The aim was to develop a facade brick that controls the wind flow in three parts:

LATTICE STRUCTURE: 1. Varying spanning lengths for different opening sizes for venturi effect of the wind. 2. Nonplanar toolpath experimentation for joints

1. External component: Wind direction. 2. Main central lattice: Wind velocity. 3. Internal component: Wind thermal.

interior

EXTERIOR PART: 1. Slope angle variation to control wind direction. 2. Experiments with stepover factor for stability in the clay complex geometries

exterior

framework

Given the surface textures, the angular double curved geometry and non-planar lattice, this two-unit facade brick is optimised for ceramic additive manufacturing with inherent reinforcement.

interior

01 Brick positioning on the primary frame

interior

exterior

02 Sectional connection detail of 2 bricks 03 Non-planar lattice for joinery of bricks 04 Top view plan of the 2-brick assembly 05 Sectional view of the 2-brick assembly

exterior

physical modelling

PLASTER MOULD & SLIPCAST

Plasterworks & Ceramics Modelling

LATTICE STRUCTURE: Lattice toolpath was initially tested for reinforcement. Further, non-planar toolpath was adapted to accommodate the joinery between bricks.

EXTERIOR PART:

03 To print overhangs and avoid collisions, the geom-

etry and toolpath was accommodated. Change in stepover value helps in adhesion of previous layer.

INTERIOR PART:

02 To create varying texture, extrusion factor was modified

as per the height which strengthens the structural support as well. This was tried in lieu of filler geometry as well.

2021/22

BARC0060: Final Major Project STUDENT NO. 20111292

PROJECT PROPOSAL

BARC0059: Initial Projects

2021/22

STUDENT NO. 20111292

global problems

IMPACTS OF AEC INDUSTRY Environmental & Technical Issues at hand

//Emissions

//Extraction

//Waste

//Energy

// 30% human-caused CO2 and 40% global green house gas emissions

// 40% global resource consumption - 10 million tons of concrete used every year

// 25% human waste by the building sector until 2050.

// 40% global energy consumptions

//United Nations and International Agency, 2017

//UNEP (UN Environment Programme 1972-2022)

MATERIALS

PROCESSES

How to develop local/natural sustainable material alternatives that have similar performances and structural behaviourial properties like conventional materials (concrete, steel and glass)?

How to find non-conventional options (fabric/ adaptive/3d printed formworks) to replace traditional ones that incorporate superfluous consumption of non-recyclable resources?

//2019 Global Status Report for Buildings and Construction

STRUCTURE How can we design using lightweight, weaker materials in accordance to stress and force flows in the structure for high strength and the role of computation and topological optimisation?

//UNEP - World Economic Forum Study, 2020

TOOLS How aspects of the production chain can be optimised - developing design support tools like multiuse end effectors for robots versus less energy intensive stereotonomic assembly techniques.

solution space

DFM & AEC INDUSTRY

Solving issues with ‘architectural ceramics’

4INTENTS

Extraction & Waste (unbalanced material lifecycle)

4PROBLEMS

4SOLUTION

High tech manufacture (fueled economic recovery)

IMPROVING PERFORMANCE

UN17 Sustainable Goal - Tackle ‘Global Material Footprint’ - Ensure Sustainable Consumption & Production Patterns

UN17 Sustainable Goal - Build Resilient Infrastructure, Promote inclusive, sustainable industrialisation & foster innovation.

____Alternating Building Material

MANAGING RESOURCE CONSUMPTION ____Efficient Manufacturing Process

MINIMISING WASTE GENERATION

____Strength through geometry

STREAMLINING DFM WORKFLOWS

____Supply Chain development tooling

ANALYSIS Performance

CERAMIC FORMULATION REINFORCEMENT

FABRIC FORM-WORK ADDITIVE MANUFACTURING

Materials

Tools & Processes

STEREOTOMIC GEOMETRY Structure

// // // //

Material Strategies Structural optimisation Economic/social Value Technological Innovation

To reduce material consumption in the building components by optimising manufacturing via novel digital-physical techniques adaptive to material behaviour.

Structual optimisation and material hybridisation

Understanding sustainable buildings

Potential of ‘Ceramics’

Advantages of Additive Manufacturing

what does the material want?

CONVENTIONAL vs NON-CONVENTIONAL Performance Gradience of ‘Architectural Ceramics’

CONVENTIONAL MATERIAL

CERAMIC ELEMENT

concern - RAW MATERIALS ?

CERAMIC FORMULATION Durability & Opacity

REINFORCEMENT Material Behaviour

the need for alternative material

CONVENTIONAL BUILDING ELEMENT

COMPARISON

concern - FABRICATION ?

concern - ASSEMBLY?

ADDITIVE MANUFACTURING

ASSEMBLY & DISTRIBUTION

FABRIC FORM-FINDING

Tools and Processes

Fired vs Unfired Clay

Tools and Processes

the need to optimise fabrication

OPTIMISED BUILDING ELEMENT

the need to simplify assembly

the need to manage construction

To develop an optimised ‘Design to Manufacture & Assembly’ Workflow of a hybrid construction system that addresses the Circular Economy in the Built Environment by tapping into the potential properties and behaviour of Architectural Ceramics in relation to conventional building materials (concrete, steel and glass)

Data Sourcing & Analysis by Minran Xue

CERAMIC INDUSTRY & CHALLENGES Stakeholders perspective - Designers & Manufacturers MACRO PROBLEM: (AEC Industry)

NDUSTRY & CERAMICS

MACRO PROBLEM: (AEC Industry)

The AEC Industry TECHNICAL PROBLEM material consumption + processing + assembly

AIM: To develop a system/tool for design and fabrication of 'architectural' ceramics - based on the potential of ceramic to be load-bearing/selfsupporting.

Extraction & Waste (unbalanced material lifecycle)

UN17 Sustainable Goal - Tackle 'Global Material Footprint' - Ensure Sustainable Consumption & Production Patterns

MESO PROBLEM (Ceramic industry) The AEC Industry Extraction & TECHNICAL PROBLEM 1. Disjunct relation between the Waste material consumption + processing (unbalanced + assembly process of ceramic production and the material

lifecycle) architect /manufacturer in the same UN17 Sustainable Goal - Tackle way as steel/concrete/timber, etc 'Global Material Footprint' - Ensure Sustainable Consumption & Production Patterns

2. lack of standard tools (for manufacturers) and design codes (for in ceramics. MESO PROBLEM (Ceramicarchitects) industry)

PROBLEM . Disjunct relation between 3.the This leads to erraticSPACE production rocess of ceramic production and the in material consumption irregularity rchitect /manufacturer in the same and waste generation in the DFM cycle. way as steel/concrete/timber, etc

. lack of standard tools (for manufacturers) and design codes (for rchitects) in ceramics.

AIM: To develop a system/tool for design and fabrication of 'architectural' PROBLEM ceramics - based on the potential of SPACE ceramic to be load-bearing/selfsupporting. INTENT: Eﬃcient communication between designers and manufacturers. Designers to look through the lens of fabricator and vice versa. OUTPUT: DFM Tool for architectural ceramics - to develop optimised geometries aimed at reducing the global material footprint.

SOLUTION RESEARCH: The role of Automation SPACE

/intelligence in determining the design space for manufacturers and testing prototypes for designers.

. This leads to erratic production regularity in material consumption nd waste generation in the DFM cycle. SOLUTION SPACE

UN17 Sustainable Goal - Build Resilient Infrastructure, Promote inclusive, sustainable industrialisation and foster innovation.

INTENT: Eﬃcient communication between designers and manufacturers. Designers to look through the lens of RESEARCH: The role of Automation/ fabricator and vice versa. intelligence in determining the design space for manufacturers and OUTPUT: testing prototypes for designers. DFM Tool for architectural ceramics - to develop optimised geometries aimed at reducing the global material footprint.

what does the industry want?

Limited labour and resources for bespoke craft.

Research for decorative rather than architectural!

RESEARCH: The role of Automation /intelligence in determining the design space for manufacturers and testing prototypes for designers.

UN17 Sustainable Goal - Build Resilient Infrastructure, Promote inclusive, sustainable industrialisation and foster innovation.

High tech manufacture (fueled economic recovery)

Finishing and precision dependent on manual labour

Intensive technology focus only for mass production

High tech manufacture (fueled economic recovery)

Conventional wasteful subtractive moulding methods

Profit driven market for conventional products

Some photographs by Minran Xue, Monisha Sridhara and Bingze Li

Superflous unsustainable material consumption

Restricted R&D in high tech manufacturing tools

research avenue

LOCAL CONTEXT & CERAMICS Proposing a social value for application

CERAMICS INDUSTRY & CHALLENGES LOW-TECH, DEVELOPING ECONOMIES WITH EMERGENCY NEEDS, BUT WITH RICH CERAMIC-CRAFT HISTORY & LOCAL AVAILABILITY OF MATERIALS. PROBLEM SPACE CERAMICS INDUSTRY & CHALLENGES Skilled labour shortage for craft-based production

R&D in high-tech systems

Gap between production timeline & Design Management

LOW-TECH, DEVELOPING ECONOMIES WITH EMERGENCY NEEDS, The need for BUT WITH RICH CERAMIC-CRAFT HISTORY & LOCAL AVAILABILITY OF MATERIALS. Haphazard material management cycle:

PROBLEM SPACE

Skilled labour Unscrupulous shortage for Gap between 1. For manufacturers: consumption of production noncraftbased production timeline & Design recyclable materials: Formwork waste generation in Management conventional production.

R&D in high-tech Haphazard material management cycle: systems2. For designers: Conventional prototyping processes leading

to poorly crafted and material-optimised products and 1. For manufacturers: Unscrupulous consumption of noncompromise in product's performance. recyclable materials: Formwork waste generation in

optimised design-toproduction workﬂows

The need for optimised design-toproduction workﬂows

SOLUTION SPACE

conventional production.

SOLUTION SPACE

2. For designers: Conventional prototyping processes leading to poorly crafted and material-optimised products and compromise in product's performance.

LOCAL CONTEXT & CERAMIC STAKEHOLDERS LOCAL CURRENT ISSUES:CONTEXT & CERAMIC Designers - multiple moulds and prototypes required to test geometric CURRENT ISSUES: performance leading to unscrupulous Designers - multiple moulds and consumption of material. prototypes required to test geometric

SOLUTION SPACE

STAKEHOLDERS SUGGESTED DEVELOPMENTS:

The need to balance between low tech resources and high tech fabrication solutions (craft vs technology).

RESEARCH: The role of Automation /intelligence in determining the design space for manufacturers and testing prototypes for designers.

Designers - Prototyping tool: Adaptive physical methods that help in testing SUGGESTED DEVELOPMENTS: performance of geometries before Designers - Prototyping tool: Adaptive ceramic production. physical methods that help in testing

POTENTIAL SOLUTIONS: Designer - Use of robotic actuation and their physical intelligence for optimised POTENTIAL SOLUTIONS: design. Designer - Use of robotic actuation and

performance leading to unscrupulous consumption of material. Manufacturer - dependence on

performance of geometries before ceramic production. Manufacturer - Design & Analysis Tool

their physical intelligence for optimised design. Manufacturer - Use of fabric formworks

conventional design methods that are Manufacturer - dependence on not ceramic material-intrinsic leading to conventional design methods that are conventional wasteful moulds. not ceramic materialintrinsic leading to

Analytic digital methods that optimise Manufacturer - Design & Analysis Tool the tooling based on the geometry Analytic digital methods that optimise before ceramic production. the tooling based on the geometry

Manufacturer - Use of fabric formworks optimised production. and their digital intelligence for optimised production.

conventional wasteful moulds.

before ceramic production.

and their digital intelligence for

state-of-the-art

MATERIAL PERFORMANCE AND BEHAVIOUR Identifying the limitations and opportunities

J Keep guide to 3D printing clay & Material Innovations

J Keep guide to 3D printing clay

ons

Data Sourcing & Analysis by Calvin Kwan & Monisha Sridhara

state-of-the-art

STRUCTURAL OPTIMISATION

Identifying the limitations and opportunities

LITERATURE REVIEW Fabric Form-Finding and 3D Printing

Armadillo Vault - Discretisation in mortarless stone stereotomy: Due to varying guassian curvature, rationalised discretisation and cutting the geometry efficiently was a difficuly task leading to a large number of pieces. No mortar is used, so precision is needed in the stone interfaces as there is no compensation for tolerance.

Striatus Bridge - Stereotomy in Concrete Additive Manufacturing: The overall assembly proces was intensive due to the heavy and densely reinforced 3D printed concrete panels with formwork. The toolpath is optimised as per the geometry but requires formwork for every piece thereby the need of flexibility of a single mould.

Architecture Hypar - Stereotomic Shell structure development: Since it was a repetition of a single geometry, it was casted within an optimised 3DP mould. However, there is waste of material with the wire cutting to chamfer the edges for stereotomy. The global geometry seeks the need for tensioned flexible scaffold systems.

Affective Thickness - Variable Casting of Geometries: An effective and optimised use of the thickness of the lightweight ceramic tiles as per material thrust analysis. They were produced by extrusion of standard geometry and each piece was customised with the robotic wire cutter leading to use of extra resources.

[1] Straitus Bridge, ETHZ, BRG [2] The Armadillo Vault, Balancing Computation and Traditional Craft, M. Block, M. Rippmann, T. Mele [3] Robotic Fabrication of Components for Ceramic Shell Structures, Z. Seibold, M. Singh, L. Tseng, Y. Wang [4] RNew Frontiers of Stone Architecture: Parametric-Computational Design, Digital Fabrication and Construction, New Fundamentals Research Group

state-of-the-art

ADAPTIVE PROCESSES

Identifying the limitations and opportunities

THE NEED FOR RE-USE & RE-CONFIGURABLE TENSIONING

AN ADAPTIVE FABRICATION SETUP THAT WORKS WITH MATERIAL BEHAVIOUR

Optimised Tooling & waste-efficient approach Tapping into the use of textiles to inform a lightweight, easily transportable and assemble design that aids in form-finding with minimal formwork and material usage. Inclusions of moulding features within the textile replaces the need for subtractive milled moulds.

Reducing emissions by pre-fabrication using traditional process. The traditional manufacturing process of slipcasting is adapted to construct offsite structural components using fabric formwork. However, are there way-arounds to limitations on size-scale of the elements and alignment of internal reinforcements while slipping?

Additional Resource Consumption for textile formwork Structured steel and wooden members alias scarce standard scaffolding, frame and cables were still used to tension the formwork. Can this be made reusable and reconfigurable actuated system in the fabrication process that guides form finding design approach?

Role of the robotic trajectory with multi-end effector tooling. Controlled dynamic hydration of the material and the robustness of the mechanical actuation play a strategic role in the fabrication use and justifying the requirement of a high-tech, sophisticated feedback approach in order to reinforce a circular design process.

state-of-the-art

HIGH-TECH TOOLS & SYSTEMS Identifying the limitations and opportunities

QUESTIONING SUBTRACTIVE MANUFACTURE & THE WASTE

HIGH TECH ROBOTICS + POTENTIALS OF ADDITIVE MANUFACTURING

// Contour Crafting

Addressing the challenges of a free-form structures This construction of the free-form formwork and its capability of reuse is developed by tapping the melting properties of wax. Also, it is based on a robotically actuated mould that does multiple simultaneous operations thereby optimising the fabrication process.

Augmentation of the 3D printing process using robotics. The key attributes of the AM, namely, material preparation, delivery, layer-by-layer fabrication, phase change of build/bond medium, support system/removal, finishing can be augmented by defining suitable toolpaths and end effectors as per structural forces and material behaviour.

Ecological and economic perspectives of the process The high amount of energy required for re-melting given the high embodied energy needs to be factored. This equivalents to single one time investmest cost in material embodied energy like wood/ EPS/polysterene subtractive methods that are waste intensive.

Hybrid manufacturing process - limitations of AM + SM Waste intensive, time consuming, geometric limitations, resource intrinsic, increased complexity, etc are concerns with mono-fabrication systems. The combination of AM + SM enhanced through responsive computational modeling may provide a potential solution to the pre-fabrication of mass customized modular architectural components.

// Thallus, AI Build, Odico

Data Sourcing & Analysis by Minran Xue

state-of-the-art

ASSEMBLY/DESIGN/STRUCTURE Identifying the limitations and opportunities

LITERATURE REVIEW Fabric Form-Finding and 3D Printing

Value addition via scaling of additive manufacturing techniques Adding value to the building element performance by addressing the geometrical challenge which relies on the understanding between material behaviour and printing process. Some ways are by using innovative hybrid techniques with insitu resources and multimaterial optimisation.

Toolpaths for fabrication large scale components Strategies applied to 3D Printing - To define a curved layering toolpath inspired by the masonry traditional vault construction techniques with/without temporary support and analyse the stability of the fabrication process at the scale of the brick, the layer and the final structure. [1] OnSite Robotics, A. Dubey, E. Cabay, IAAC, Technalia

Design and manufacture for Assembly - optimisation techniques In the above scenarios, the sensitivity of the materials and processes to ambient conditions can hamper on-site manufacture. On the other hand, the modules can be manufactured offsite and assembly onsite. ssentially, the project needs to strike a balance between moving fully assembled, over large distances, versus utilising local construction expertise and robotics for the final assembly available on the site.

Structural development with a weaker material How can one achieve strength through geometry by maintaining structural equilibrium in design and fabrication process rather than investing in material strength. This can be of help in developing contexts where locally sourced weak materials can be used for sustainable alternatives for conventional constructions.

[2] Angled Vault & Squinch Printing, Studio One, UC Berkeley [3] Sandy Curth, Computation, MIT [4] Integrated Form finding and Robotic Technologies to Reduce Construction Waste, SOM, Create Lab, Princeton University.

state-of-the-art

CLAY-FABRIC BEHAVIOUR

Identifying the limitations and opportunities

Y/SKILLS/INITIAL PROJECTS HEORY/SKILLS/INITIAL PROJECTS

ONTEXTUAL THEORY/SKILLS/INITIAL PROJECTS CONTEXTUAL THEORY/SKILLS/INITIAL PROJECTS

Flexibility of the Fabric Flexibility of the L:POTENTIAL: Flexibility of the POTENTIAL: POTENTIAL: Flexibility of the POTENTIAL: of the fabric aidsaids inFlexibility formfabric in form-finding. finding. fabric aids in form-finding. in formfinding. fabric aids in form-finding. DRAWBACK: Optimising the

DRAWBACK: Optimising the Optimising the tensioning system DRAWBACK: OptimisingDRAWBACK: the system K: Optimising the tensioning sturdiness. tensioning system -- sturditensioning system - sturdiness. ness.

system -

sturdiness.

FABRIC

FABRIC QUESTION RESEARCH

Clay POTENTIAL: Lightweight POTENTIAL: Lightweight POTENTIAL: Lightweight POTENTIAL: Lightweight POTENTIAL: Lightweight and low densityby and low density +byagility and density low density and low +agility agility by +byagility by and+low density + agility its plasticity, gravity and itsgravity plasticity, gravity and its plasticity, and its plasticity, gravity and its plasticity, gravity and machine behaviour. machine behaviour. machine behaviour. machine behaviour. machine behaviour. DRAWBACK: Structural Clay + Fabric

POTENTIAL: Robustness, low cost and ﬂexible. DRAWBACK: lack of 3D shaping, branching and hollow void geometries

DRAWBACK: Structural DRAWBACK: Structural POTENTIAL: Robustness, stability DRAWBACK:stability Structural low cost and flexible. CLAY DRAWBACK: Structural DRAWBACK: lack of 3D stability CLAY shaping, branching and stability hollow void geometries. stability

CLAY

CLAY + FABRIC

POTENTIAL: Robustness, lowlow low POTENTIAL: Robustness, POTENTIAL: Robustness, cost and and flexible. cost flexible. cost and flexible. DRAWBACK: lack of 3D shaping,

DRAWBACK: lack of 3D shaping, branching and hollow DRAWBACK: lackvoid of 3D shaping, branching and hollow void geometries branching and hollow void geometries

geometries

CLAY + FABRIC

FABRIC

CLAY

RESEARCHTHEORY/SKILLS/INITIAL QUESTIONS CONTEXTUAL PROJECTS

Knowledge contribution & addressing gaps

RESEARCH QUESTION POTENTIAL: Flexibility of the fabric aids in form-ﬁnding. DRAWBACK: Optimising the tensioning system sturdiness.

POTENTIAL: Lightweight and low density + agility by its plasticity, gravity and machine behaviour.

How can digital encoding of fabric DRAWBACK: Structural stability formwork and physical tensioning FABRIC CLAY system aid in variable casting of stereotomic ceramic assemblies?? CONTEXTUAL THEORY/SKILLS/INITIAL PROJECTS RESEARCH QUESTION How can digital encoding ofPOTENTIAL: fabric Flexibility of the fabric aids in form-ﬁnding. formwork and physical tensioning DRAWBACK: system aid in variable casting of Optimising the tensioning system stereotomic sturdiness. //Robotic ceramic assemblies?? //Collaborative

STATE-OF-THE-ART

Programming Interface

//End Effector Design

Interface Setup FABRIC (Feedback)

RESEARCH STATE-OFTHE-ART QUESTION How can digital encoding of fabric formwork and physical tensioning system aid in variable casting of stereotomic ceramic assemblies??

STATE-OF-THE-ART

POTENTIAL: Lightweight and low density + agility by its plasticity, gravity and machine behaviour. DRAWBACK: Structural //Overall stability Fabrication CLAY Platform

Digital materiality - Robustness, How canlowwe develop the DFMA workflow for robot POTENTIAL: cost and ﬂexible. supported materialisation processes where the robot reacts and anticipates material behaviour there is a continuous feedback loop involved. DRAWBACK: lack of and 3D shaping, branching and hollow void geometries

To develop adaptive fabrication sequences that rely on the feedCLAY + FABRIC back between material behaviour and the formwork geometry. How can robotic positioning of fabric formwork aid in ceramic agility and performance to ensure sustainable material lifecycle patterns? How to standardise the use of the robot/or develop novel DIY highPOTENTIAL: Robustness, low cost and ﬂexible. end tools in the manufacturing process - at the factory and at the site, alongside digital andDRAWBACK: analogue in low-tech economies?? lack ofcraftsmen 3D shaping, branching and hollow void geometries

To develop a nested tool (end effector for a robot) that integrates multiple fabrication sequences slipcast/ binderCLAY + FABRIC (3DP/ jet/ actuation/ assembly, etc) in adaptation to material behaviour.

CLAY + FABRIC

OBJECTIVES OBJECTIVES

Tests to Further Address the Project Aim

documentation

FEASIBILITY TESTS & TRIALS Preliminary Scoping Trials

//Clay formulation

// Understanding workability, durability and plasPROJECT PROJECT ticity of various combinaOBJECTIVES OBJECTIVES tions of clay and additives

// Checking behaviour of different fabrics and clay in terms of manufacturing techniques, tensioned systems

//Fabric Formwork and formfinding

//Clay & Glass composite

clay formulation

//Testing material behaviour in terms of strength Tests to Further and translucency with Address the Project Aim different glass infusions.

// To find out the better fiber and techniques needed in certain context in terms of feasibility and performances

//Extrusion & Fibre Reinforcement

fabric formwork

documentation

EXPERIMENTS - CLAY FORMULATION Explore clay rheology and properties

STANDARDISED PROCEDURES - EVALUATION CRITERIA STANDARDISED PROCEDURES - EVALUATION CRITERIA

Porcelain like mix to test out : drying time - rapid plasticity - low Porcelain like mix workability to test out : drying time - rapid plasticity - low workability

+ DFAC - Drying factor + DFAC - Drying STANDARDISED factor PROCEDURES - EVALUATION CRITERIA + SHAB - Shrinkage/ Absorption

STANDARDISED STANDARDISED PROCEDURES PROCEDURES - EVALUATION - EVALUATION CRITERIA CRITERIA Porcelain like mix

+ SHAB - Shrinkage/ Absorption RAW RAW MATERIALS MATERIALS - VARIABLES - VARIABLES + LDW – LOI / Water content

+ DFAC - Drying factor STANDARDISED

LES

Porcelain like mix to test out : drying time - rapid plasticity - low workability

Testing out workability of mix Requires plasticizer Testing out workability of mix Requires plasticizer

+ LDW – LOI / Water content + Optronic light permeability

PROCEDURES - EVALUATION CRITERIA

+ SHAB - Shrinkage/ Absorption

+ Optronic light permeability + Plasticity

+ DFAC - Drying factor + LDW – LOI / Water content

+ Plasticity + Drop spike for consistency

+ SHAB - Shrinkage/ Absorption + Optronic light permeability

+ Drop spike for consistency + Syringe extrusion for +flow rate Plasticity

+ LDW – LOI / Water content

Porcelain like mix Porcelain + Optronic light: drying permeability tolike testmix out time - rapid + Drop spike for consistency to test out : drying time- -low rapid plasticity plasticity - low workability + Plasticity workability

+ Syringe extrusion for flow rate

EDURES EVALUATIONCRITERIA CRITERIA DURES - -EVALUATION

+ Syringe extrusion for flow rate

+ Drop spike for consistency + Syringe extrusion for flow rate

orption rption

low rate ow rate

Light transmission test Planar - high Light transmission test Extrusions - minimal Planar - high Extrusions - minimal

Varied rate of drying causing shrinkage & warp in samples Light transmission test Planar - high shrinkage rate due to increased surface area Planar - high Extrusions - workability linear shrinkage israte lesser than planar Extrusions - minimal Varied Varied rate of drying of drying causing causing shrinkage shrinkage & warp & warp in samples in samples Testing Testing outout workability of mix of mix which

Requires plasticizer

Light Light transmissio transmis Planar Planar - high - high shrinkage shrinkage raterate duedue to increased to increased surface surface area area Planar Planar - high - high Extrusions Extrusions - linear - linear shrinkage shrinkage which which is lesser is lesser than than planar planar Extrusions Extrusions - minim -m Analysing deformations

Requires Requires plasticizer plasticizer

+ DFAC + DFAC - Drying - Drying factor factor

Before firing

+ SHAB + SHAB - Shrinkage/ - Shrinkage/ Absorption Absorption

Before firing

Testing out workability of mix Requires plasticizer

Varied rate of drying causing shrinkage & warp in samples Planar - high shrinkage rate due to increased surface area Analysing deformations Extrusions - linear shrinkage which is lesser than planar

Light transmission test Planar - high Extrusions - minimal

mixcontent - lower water % + LDW + LDW –Porcelain LOI – LOI / Water / Water content to test out : state after firing Porcelain mix - lower water % + Optronic + Optronic light light permeability permeability translucency

Before firing

Analysing deformations Analysing Analysing deformations deformations

Before Before firing firing

to test out : state after firing + Plasticity + Plasticity translucency Porcelain mix - lower water %

After firing

Lower water content allows for better form retention Analysing deformations Extrusions exhibit minimal deformations firing to test to test out out : state : state afterafter firing firing translucency translucency Lower water contenthigh; allows for betteron form retention Planar deformations dependant scale & form + Syringe + Syringe extrusion extrusion for for flow flow raterate Extrusions exhibit minimal deformations Varied of drying causing shrinkage & warp in firing samples Light transmission test Testing out workability of mix - lower rate waterAfter firingcausing firing Varied rate of%drying shrinkage & warpAfter inAfter samples Light transmission test Testing out workability of mixPorcelain mix Planar deformations high; dependant on scale & form Planar - high shrinkage rate due to increased surface area Planar - highLower water content allows for Requires plasticizer Lower Lower water water content content allows allows for for better better form form reten re better form retention Planar high shrinkage rate due to increased surface area Planar high Requires plasticizer to test out : state after firing Extrusions Extrusions exhibit exhibit minimal minimal deformations deformation Extrusions linear shrinkage which is lesser than planar Extrusions minimal Extrusions exhibit minimal deformations translucency - linear shrinkage which is lesser than planar Extrusions Extrusions - minimal Planar Planar deformations deformations high; high; dependant dependant on on scale scale & Porcelain Porcelain mix mix - lower - lower water water % %

Before firing

+ Drop + Drop spike spike for for consistency consistency

to test out : state after firing After translucency

RAW MATERIALS - VARIABLES

STANDARDISED PROCEDURES - EVALUATION CRITERIA

After firing STANDARDISED PROCEDURES - EVALUATION CRITERIA

RAW MATERIALS - VARIABLES

Porcelain like mix to test out : drying time - rapid Porcelain like mixplasticity - low to test outworkability : drying time - rapid

Planar deformations high; dependant on scale & form

plasticity - low workability

Lower water content allows for better form retention Varied rate of drying causing shrinkage & warp in samples Light transmission test high shrinkage rate due&towarp increased surface area Planar - high exhibit minimal deformations VariedPlanar rateExtrusions of-drying causing shrinkage in samples Light transmission test - linear shrinkage which is lesser thanarea planarPlanar Extrusions - minimal Planar - high shrinkage rate due to increased surface - high Rate of drying - Extrusions significant variation Planar deformations dependant on scale Extrusions - linear shrinkage whichhigh; is lesser than planar Extrusions - minimal& form

Testing out workability of mix Requires plasticizer Testing out workability of mix Requires plasticizer

+ DFAC - Drying factor + DFAC - Drying factor

+ SHAB - Shrinkage/ Absorption + SHAB - Shrinkage/ Absorption

bility ility

RIA RIA

Porcelain Porcelain like like mix mix to test to test out out : drying : drying timetime - rapid - rapid plasticity plasticity - lowlow Testing out workability of mix workability workability

to test out : drying time - rapid plasticity - low workability

ntent ent

ency ncy

Varied rate of drying causing shrinkage & warp in samples Planar - high shrinkage rate due to increased surface area Varied rate of -drying shrinkage warpthan in samples Extrusions linearcausing shrinkage which is&lesser planar Planar - high shrinkage rate due to increased surface area Extrusions - linear shrinkage which is lesser than planar

+ LDW – LOI / Water content

Before firing Before firing

+ Optronic light permeability

Analysing deformations Analysing deformations

+ Optronic light permeability

+ Plasticity

Porcelain like mix Porcelain like mix to test out : drying time - rapid to test out : drying time - rapid plasticity - low plasticity - low workability workability

Porcelain mix - lower water % Porcelain mix - lower water % to test out : state after firing to test out : state after firing translucency translucency

LOI - Fired Weight / Dry Weight * 100Testing out workability of mix Testing Wet Weight - Dry Weight / Wet Weight * 100 out workability of mix

Requires Requires plasticizer plasticizer

LOI - Fired Weight / Dry Weight * 100 LOI - Fired Weight / Dry Weight * 100 Wet Weight - Dry Weight / Wet Weight * 100

Wet Weight - Dry Weight / Wet Weight * 100

+ Drop spike consistency + Dropfor spike for consistency

Mix 2 - to study 3DP clay

+ Syringe extrusion for Mix 2 - to 3DP clay Mix 2extrusion -study to flow study 3DP clay + Syringe forrate flow rate

Porcelain mix - lower water %

to test outout : state after to test : state afterfiring firing translucency translucency

to test out : drying time - slow Mix 2 - to study 3DP clay to test out out : drying timetime - slow to test : drying - slow plasticity - good plasticity - good plasticity - good Mix 2 - to study 3DP clay workability workability workability to test out : drying time - slow LOI -LOI Fired - Fired Weight Weight / Dry/plasticity Dry Weight Weight 100 100 to* test outshrinkage : drying time& - slow -*good Varied rate of drying causing warp in samples Light transmission WetWet Weight Weight -of Dry- drying Dry Weight Weight / Wet / Wet Weight Weight * shrinkage 100 * 100 Varied rate causing & warp in samples Light transmission test test After firing good workability rate plasticity Planar - high shrinkage due to -increased surface area Planar - high

AfterPlanar firing- high shrinkage rate workability due to increased surface area Extrusions Extrusions -- linear linear shrinkage shrinkage which which is is lesser lesser than than planar planar Mix 2 - to study 3DP clay

to test out : drying time - slow plasticity - good workability

Rate of drying significant Planar - fast -(high surfacevariation area) Rate Rate of drying of drying - significant - significant variation variation Extrusions - slow Rate of drying - significant variation Planar Planar - fast - fast (high (high surface surface area) area) Planar - fast of (high area) Analysing deformations Before firing Addition grogsurface reduced Analysing deformations Before firing Extrusions Extrusions - slow - slow Extrusions slow Planar - fast (high surface area)Addition Addition of grog of grog reduced reduced Addition of grog -reduced Extrusions slow Addition of grog reduced Rate of drying - significant variation After firing firing

Lower waterwater content allowsallows for better retention Lower content for form better form retention

Extrusions exhibit minimal deformations Extrusions exhibit minimal deformations Planar - fast (high surface area) Planar deformations high; dependant on scaleon & scale form & form Planar deformations high; dependant Extrusions - slow Addition of grog reduced

Planar - high Lower water content allows for better form retention Lower water content allows for better form retention Extrusions Extrusions -- minimal minimal Extrusions exhibit minimal deformations Extrusions exhibit minimal deformations Planar deformations high; dependant on scale & form Planar deformations high; dependant on scale & form

Experiments by Monisha Sridhara Rate of drying - significant variation

Rate of drying - significant variation

Planar - fast (high surface area) Planar - fast-(high Extrusions slow surface area) - slow Addition ofExtrusions grog reduced

Addition of grog reduced

LOI - Fired Weight / Dry Weight * 100 Wet Weight - Dry Weight / Wet Weight * 100

Mix 2 - to study 3DP clay

to test out : drying time - slow plasticity - good

LOI - Fired Weight / Dry Weight * 100 Wet Weight - Dry Weight / Wet Weight * 100

LOI - Fired Weight / Dry Weight * 100

to test out : drying time - slow workability plasticity - good workability

documentation

EXPERIMENTS - COMPOSITE MATERIAL

: Amplify the ofitan light inbe ceramics itancould be lost due to an increase inofthe mass/ thickness of application) by developing ifylight the INTENT transmission ofitlight intransmission ceramics (asglass could lost to increase inof the mass/ thickness application) by developing a ceramic-glass of in ceramics (as could be lost to increase indue the(as mass/ thickness application) by developing a ceramic-glass composite and havingcomposit it a ce Developing material by combining claydue and

adhere tobydesign requirement by material optimization. n requirement material optimization. aterial optimization.

the transmission INTENT : of Amplify light inthe ceramics transmission (as it could of light be in lost ceramics due to an (asincrease it could be in the lostmass/ due tothickness an increase of application) in the mass/bythickness developing of application) a ceramic-glass by developing compositeaand ceramic-glass having it compo

INTENT :commercially Amplify transmission of material light in ceramics (as itas could be lost due to an increase in the mass/ thickness of application) by developing a ceramic-glass composite and having it of glass available to be used raw material commercially available to bethe used as raw eequirement to beForms used material adhere byas material toraw design optimization. requirement by material optimization. adhere to design requirement by material optimization.

+ Glass++powder (fine) + Glass (coarse) + Glass fibre/ roving ss powder (fine) Glassfibre/ frit (coarse) fibre/ roving + Glass stringers + Glass frit (coarse) Glass roving + Glass +frit Glass stringers + Glass beads

+ Glass + Glass beads +stringers Glass pieces

+ Glass beads + Glass pieces

+ Glass pie

Forms glass commercially available to to be as raw material mmercially Forms available of glass to of be commercially used as rawavailable material beused used as raw material

powder (fine)

+ Glass powder (fine)

+ Glass frit (coarse) + Glass fibre/ roving

+ Glass stringers

+ Glass + Glass powder frit (coarse) (fine) + Glass+fibre/ Glass roving frit (coarse) + Glass + Glass fibre/ stringers roving

Glass fibres Woven rovings Tissue mat To study material behavior, fusing scenarios, ability to transmit light by alternating layers of clay & glass

Glass fibres - fails to adhere onto clay;

+ Glass beads

+ Glass + Glass beads stringers

influences geometry underweight

mix 1 – experimental firing to observe response of fibres to cracks

+ Glass pieces

++Glass Glasspieces beads

+ Glass pieces

An attempt to standardize sample generation To test out different densities of fibre strands, their ability to fuse & possible light transmission

Glass fibres fibresmix - fails adhere ontofiring clay;to influences underweight mix 1 –toexperimental togeneration fibres - fails to adhere onto clay; Glass influences geometry underweight mix 1geometry – experimental firing to Glass fibres - fails to adhere onto clay;Glassinfluences geometry underweight 1 – to experimental An attempt to standardize sample ge An attempt standardize firing sample Woven rovings Tissue mat ven rovings Tissue mat observe response of fibres to cracks observe response of fibres to cracks observe response of fibres to cracks To study material behavior, fusing scenarios, ability test out different densities of fibre terial behavior, fusing scenarios, ability To test out different densities of fibre To strands, ty Glass fibres Glass fibres - fails to adhere onto clay; influences Glass geometry fibres - fails underweight to adhere onto clay; mix influences 1 – experimental geometryfiring underweight to mix 1 – experimental firing Anto attempt to standardize sample generation An attempt to standardize sam transmit by alternating layers their ability to fuse & possible light tra ight by alternating clay & Woven glasslight theirtoability ss ovings Tissuelayers mat ofto rovings Tissue matof clay & glass observe response of fibres to cracks observe response of fibres cracksto fuse & possible light transmission

To study material behavior, fusing scenarios, ability l behavior, fusing scenarios, ability to transmit light by alternating layers of clay & glass by alternating layers of clay & glass

clay with optic fibres test out light transmission

clay with optic fibres test out light transmission clay with optic fibres test out light transmission th optic fibres test out light transmission clay with optic fibres test out light transmissionclay with optic fibres test out light transmission

To test out different densities of fibre strands, To test out different densities o their ability to fuse & possible light transmissiontheir ability to fuse & possible lig

clay slip & glass fibre mesh - test out different densities of fibre strands, their ability to fuse & possible light transmission

clay slipdensities glass mesh - test out different of fibre light strands clay slip & glass fibre mesh - test out different of fibre strands, their ability todensities fuse & possible tra clay slip & glass fibre mesh - test out different densities of fibre strands, their ability to&fuse & fibre possible light transmission

clay slip & glass fibre mesh - test out different densities clay slip & of glass fibre strands, fibre mesh their - test ability out to different fuse & densities possible light of fibre transmission strands, their ability to fuse & possible lig

Experiments by Monisha Sridhara

extrusions

We also looked at fiber reinforcement and extrusion materials but zoning in on the reinforcement, we broke it down into structure and material for what we are looking at and considering the possible options. For this test, we looked at short whisker fibers since we can control the alignment through extrusion while on the material side we looked at glass since they can withstand the high temperatures in the kiln. But that’s not to say natural fibers are ruled out since they still have an application in unfired clays.

alignment

Assessing fibre reinforcement material options

We looked into the alignment of fibers so first taking a look at a parallel cut along the extrusion direction, we can see the fibers have some alignment in the extrusion direction in the 10% and 20% volume percentage so there is potential for effective alignment but distribution is to be explored. Next was a perpendicular cut across the extrusion path where we can see a cross-section but fibers impart more pores which weakens the clay so there is a tradeoff that comes with the fiber-clay ratio.

structural

documentation

EXPERIMENTS - FIBRE REINFORCEMENT

Next we did some preliminary structural tests with a 3DP conical nozzle where the taper angle dictates flow and fiber alignment. In the flexural strength tests, a point load is applied to the middle where we saw the bottom layer fracture under tension but exhibit fiber pullout failure where the clay has failed but not the fibers. As for compression, fibers have minimal impact on the compressive strength as the fibers still hold the two clay pieces at the fracture plane where it would typically just crumble. Experiments by Calvin Kwan

Formfinding and structures using fabric formworks

01 Testing different boundary conditions to derive structural efficient geometries

Looking deeper into shell Selecting the type of geometry structures - focus into 'form Freeform (NURBS - do not passive' structural systems that consider Looking deeper dointo notshell actively changeSelecting shape the type of structure)/Mathematical geometry (based structures - focus intoloads 'formunlike 'form active' Freeform (NURBS - do not under on functions)/Form found passive' structural systems that consider membrane or cable structures. (Natural,hanging shapes) do not actively change shape

structure)/Mathematical (based under loads unlike 'form active' on functions)/Form found Looking deeper into shell membrane or cable structures. (Natural,hanging shapes) structures - focus into 'form passive' structural systems that FORM PASSIVE STRUCTURES FORMGEOMETRY doFOUND not actively change shape FORM PASSIVE STRUCTURES

FORM-FOUND GEOMETRY

under loads unlike 'form active' membrane or cable structures.

Looking deeper into shell structures - focus into 'form passive' structural systems that do not actively change shape under loads unlike 'form active' membrane or cable structures.

Selecting the type of geometry Freeform (NURBS - do not consider structure)/Mathematical (based on functions)/Form found (Natural,hanging shapes)

02 Understanding effects of loading and forces on the stretched tensioned fabric. 03 Checking clay-fabric material behaviour in-reponse to the physical conditions.

FORM PASSIVE STRUCTURES

Selecting the type of geometry Freeform (NURBS - do not consider structure)/Mathematical (based on functions)/Form found (Natural,hanging shapes)

FORM-FOUND GEOMETRY

FORM-FINDING GEOMETRY

FORM PASSIVE STRUCTURES

FORM-FINDING Deﬁne the parameters for the GEOMETRY same? OPTIMISATION

FORM-FINDING GEOMETRY

GEOMETRY

OPTIMISATION

Boundary Conditions

FORM-FOUND GEOMETRY

Supports

OPTIMISATION Supports Applied Loads Deﬁne the Boundary Conditions Boundary Conditions Supports parameters Deﬁne the FORM-FINDING for the parameters Formwork of the model Internal forces HOW DO material same?Topology of the for model the TopologyInternal forces Looking deeper into shell structures - focus into 'form passive' structural systems that do not actively change shape under loads unlike 'form active' membrane or cable structures.

FORM PASSIVE STRUCTURES

same?

OPTIMISATION

FORM-FOUND GEOMETRY

GEOMETRY OPTIMISATION

HOW DOHOW DO SHELL WORKS? SHELL WORKS?

Applied Loads Topology of the model

Supports

Applied Loads

Internal forces

Formwork material

STRUCTURAL INTELLIGENCE IN FLEXIBLE MATERIALS

characteristics Formwork material Boundary Conditions characteristics

parameters for the same?

Topology of the model

1. What is the advantage of funicular forms? tension only/compression only? - minimal HOW area, DO maximum volume and optimised structure?

ONLY)!! PHYSICAL MATERIALS Applied Loads FORM-FINDING STRUCTURAL Supports

Internal forces

Formwork material characteristics

Flat fabrics to form 3D funicular structures

PHYSICAL

(COMPRESSION DIGITAL ONLY)!!

INTELLIGENCE IN FLEXIBLE MATERIALS

HOW DO SHELLS WORK? LOOKING INTO FUNICULAR SHELLS (COMPRESSION ONLY)!!

FORMFINDING

What are the objectives for form-ﬁnding: boundary conditions and load cases; material properties; stresses and displacements;

DIGITAL FORM-

FORM-FINDING SHELL WORKS? PHYSICAL DIGITAL FORM-FINDING DIGITAL FORMPHYSICAL DIGITAL FORM2. Aim - to naturally develop a fabric formwork FORM-FINDING FINDING - identify stress forces and then develop

HOW DO SHELL WORKS?

HOW DO SHELLS WORK? LOOKING INTO FUNICULAR SHELLS (COMPRESSION ONLY)!!

characteristics HOW DO SHELLS STRUCTURAL HOW DO SHELLS WORK? LOOKING INTO STRUCTURAL INTELLIGENCE IN Applied Loads WORK? LOOKING INTO HOW DO SHELLS FUNICULAR SHELLS INTELLIGENCE IN STRUCTURAL FLEXIBLE FUNICULAR SHELLS WORK? LOOKING INTO (COMPRESSION FLEXIBLE INTELLIGENCE IN (COMPRESSION FUNICULAR SHELLS Formwork material ONLY)!! FLEXIBLEMATERIALS MATERIALS

Selecting the type of geometry Freeform (NURBS - do not consider structure)/Mathematical (based on functions)/Form found (Natural,hanging shapes)

FORM-FINDING

Boundary Conditions

Deﬁne the parameters for the same?

characteristics Topology of the SHELL model WORKS? Internal forces Deﬁne the

PHYSICAL FORM-FINDING FORM-FINDING

structure in accordance to that to address

1.deformation What is the advantage of funicular forms? tension only/compression only? - minimal area, maximum volume and optimised structure?

FINDING Flat fabrics to form 3D funicular structures

The alternative of a woven, orthotropic material of negligible in-plane shear resistance, is characterised by the orientation of the ﬁbres.

FINDING

What are the objectives for form-ﬁnding: boundary conditions and load cases; material properties; stresses and displacements;

The alternative of a woven, orthotropic material of negligible in-plane shear resistance, is characterised by the orientation of the ﬁbres.

What are the objectives for form-finding: The alternative of a woven, orthotropic boundary conditions and load cases; material of negligible in-plane shear What are the objectives for material form-finding: orthotropic properties; The alternative of a woven, resistance, is characterised by the boundary conditions and load cases; material of in-plane shear What aredisplacements; the objectives fornegligible form-finding: The alternative of a stresses and form 3D orientation of the fibres. 2. Aim - to naturally develop a fabric formwork

1. What is the advantage of funicular forms? Flat fabrics to form 3D tension only/compression only? - minimal funicular structures 1. What is the advantage of funicular forms? area, maximum volume and optimised structure? tension only/compression only? minimal 1. What is the advantage of funicular forms? -

area, maximumtension volume and optimised only/compression only? - minimal 2. Aim - to naturally develop a fabric formwork structure?

Flat fabrics -to form 3D identify stress forces and then develop structure in accordance to that to address funicular structures deformation

woven, orthotropic resistance, is characterised by thematerial of negligible in-plane shear boundary conditions and load cases; stresses and displacements; material properties; orientation of the ﬁbres. resistance, is characterised by the stresses and displacements; orientation of the ﬁbres.

Flat fabrics to material properties; funicular structures

area, maximum volume and optimised - identify stress forces and then develop structure in accordance to that to address structure?

2. Aim - to naturally develop a fabric formwork deformation - identify stress forces and then develop 2. Aim - to tothat naturally develop a fabric formwork structure in accordance to address deformation - identify stress forces and then develop

structure in accordance to that to address deformation

'ﬂexible self-forming' funicular moulds = 'self-construct' optimised structural shapes 'ﬂexible self-forming' funicular moulds = 'self-construct' optimised structural shapes

tensile capacity formwork membrane complements capacity of reinforced ceram tensile capacity of of formwork membrane complements compressive compressive capacity of reinforced ceramic Physical Physical Form-ﬁnding

Form-ﬁnding

'ﬂexible self-forming' Understanding concrete-fabric structural behaviour

SUB PARAMETERS: KEY PARAMETERS: 1. Impact of material elasticity, 1. BOUNDARY SUB PARAMETERS: KEY PARAMETERS: shrinkage and creep. CONDITION/SUPPORTS 2. Mechanical properties of 1. Impact of material elasticity, 2. LOADS 1. BOUNDARY material - density, stiﬀness. shrinkage and creep. 3. Non mechanical prop 3. MATERIAL BEHAVIOUR CONDITION/SUPPORTS temperature, moisture, etc. 2. Mechanical properties of 2. LOADS material - density, stiﬀness. 3. Non mechanical prop 3. MATERIAL BEHAVIOUR temperature, moisture, etc.

funicular moulds = 'selfconstruct' optimised structural shapes Defining parameters for physical form-finding using fabric formwork

tensile capacity of formwork membrane complements compressive capacity of reinforced ceramic dary conditions

'ﬂexible self-forming' funicular moulds = 'self-construct' optimised structural shapes KEY PARAMETERS:

SUB PARAMETERS:

1. Impact of material elasticity, 1. BOUNDARY Physical tensile capacity of formwork membrane complements compressive capacity of reinforced ceramic shrinkageoptimised and creep. 'ﬂexible self-forming' funicular moulds = 'self-construct' structural shapes

CONDITION/SUPPORTS

documentation

EXPERIMENTS - FABRIC FORMWORK

2. Mechanical properties of

documentation

EXPERIMENTS - FABRIC FORMWORK Tooling development for testing boundary conditions

'ﬂexible self-forming' funicular moulds = 'self-construct' optimised structural shapes tensile capacity of formwork membrane complements compressive capacity of reinforced ceramic

Physical Form-ﬁnding

KEY PARAMETERS: 1. BOUNDARY CONDITION/SUPPORTS 2. LOADS 3. MATERIAL BEHAVIOUR

SUB PARAMETERS: 1. Impact of material elasticity, shrinkage and creep. 2. Mechanical properties of material - density, stiﬀness. 3. Non mechanical prop temperature, moisture, etc.

01 Defining the anchors,boundary

1. Boundary conditions

conditions for funicular forms

An adjustable table was made to help with fabric manipulation and to understand the feasibility of hanging sheet mould and the performance of different fabric acting as formwork. Have the clay slab rest on the level surface first, and then raise the corners of the fabric to and naturally form a Woven polypropylene (non-elastic non-stickable to clay) shape according to gravity. Observations are as:

Woven polypropylene (non-elastic and non-stickable to clay) as formwork

LEARNING FABRIC TENSIONING SYSTEMS FROM MARK WEST

SETTING UP TOOLING FOR TESTING BOUNDARY CONDITIONS

PRECEDENCE EXAMPLE

2.Pre tensioning and Loads Variation

Lycra (elastic and slightly stickable to clay) as formwork / muslin embedded as reinforcement

● ● ●

1. Varying the tension changed the structural behaviour of fabric which reflected on the clay. 2. Shrinkage and clay thickness varies as per the fabric used due to the adherance properties. 3. Additional tension, demoulding and calculated actuation is needed to derive optimised forms.

Easy to crack on the sloping area Curvature differs according to elasticity of fabric Feasible to create shapes with multiple weaves with lycra with extra supports beneath the fabric

Lycra (elastic and slightly stickable to clay) as formwork / m

● ● ●

Easy to crack on the sloping area Curvature differs according to elasticity of fabric Feasible to create shapes with multiple weaves with l

Experiments supported by Minran Xue

haviour

Woven Polypropylene

Non-polar so mineral contaminants will not adhere to the fabric

High degree of elasticity

Lycra

1.Type of fabric Polyethylene/Polyprop elene - GEOTEXTILES sustainability??

documentation

EXPERIMENTS - FABRIC FORMWORK

Checking clay-fabric behaviour with set parameters

02 Observing the behaviour of dif● ● ●

ferent clay % with types of fabric

On muslin / lycra / ripstop / woven polypropylene Set on different angled surfaces (30 / 45 / 60) Theperpendicular terracotta extruding earthenware With vertical and angle clay was

mixed with different percentages of water and extrusion tests with fabrics. The tensioning scale, type of fabric, varying sloping angles were set parameters.

It was observed that elastic fabrics have good adhesion. Hence this comConclusion posite behaviour shall help in stay-in● Perpendicular extruding angle helpsHowever, with even the woven place formwork. extrusion fabrics does not adhere well, but, the ● Different angled surfaces make little difference is uniform ● Muslin / lycra drying exhibit good adhesion tofor clay,the clay and Fabric Fabric Fabric Fabric properties properties Fabric properties properties properties shrinkage/deformation miniwhereas ripstop /woven polypropylene are the is mal. This has potential for re-usopposite able properties demouldable moulds. Fabric ● ● ●

On muslin / lycra / ripstop / woven polypropylene Set on different angled surfaces (30 / 45 / 60) With vertical and perpendicular extruding angle

● ● ●

On muslin / lycra / ripstop / woven polypropylene Set on different angled surfaces (30 / 45 / 60) With vertical and perpendicular extruding angle

Conclusion

Muslin Muslin Muslin MuslinMuslin Muslin

Lycra Lycra LycraLycra Lycra Lycra

Ripstop Ripstop Ripstop Ripstop Ripstop Ripstop

Woven Woven Woven Polypropylene Woven Polypropylene Polypropylene Woven Polypropylene Polypropylene Thin Thin Fusing Thin Fusing Thin Fusing Fusing Thin Fusing Woven Polypropylene Thin Fusing

Permeable Permeable Permeable Waterproof Permeable Waterproof Permeable Permeable Permeable Permeable Permeable Permeable Permeable Permeable Permeable Waterproof Waterproof Waterproof Waterproof WaterproofPermeable Permeable Permeable Permeable Permeable Waterproof Waterproof Waterproof Waterproof Waterproof Notelastic elastic Elastic Elastic Not Not elastic NotNot elastic NotNot elastic Not elastic elastic Not elastic Not Elastic Elastic Elastic Elastic NotNot elastic Not elastic elastic Notelastic elastic Not elastic NotNot elastic Not elastic elastic Not elastic Not elasticNot elastic Not elastic elastic Not elastic Not elastic Loose in texture Tight in texture Tight in texture Loose in texture Tight in texture Loose Loose Loose in texture Loose inin texture texture Loose in texture in texture Tight Tight Tight in texture in Tight in texture texture in Tight texture in texture Tight Tight Tight in texture in Tight in texture texture in Tight texture in texture Loose Loose Loose in texture Loose inin texture texture Loose in texture in texture Tight Tight Tight in texture in Tight in texture texture in Tight texture in texture Very soft Very soft Soft Soft Bit hard VeryVery soft Very soft Very soft soft Very soft VeryVery soft Very soft Very soft soft Very soft SoftSoft Soft Soft Soft SoftSoft Soft Soft Soft Bit Bit hard Bit hard hard Bit hard Bit hard

Perpendicular extruding angle helps with even extrusion ● Different angled surfaces make little difference ● Muslin / lycra exhibit good adhesion to clay, Conclusion whereas ripstop /woven polypropylene are the opposite ● Perpendicular extruding angle helps with even extrusion ● Different angled surfaces make little difference ● Muslin / lycra exhibit good adhesion to clay, whereas ripstop /woven polypropylene are the opposite ●

documentation

EXPERIMENTS - FABRIC FORMWORK Tooling development for testing boundary conditions

● ● ● ● ●

03 Surface conditions of the composite

Stitch two type of fabric in a pattern Pre-form the fabric with tension to form a doubly curved surface Dip the fabric in earthenware clay When the clay dry out, apply another layer of earthenware by brush Repeat this several times

material - clay slip & tensioned fabric

With the previous test, we came up with the dipping test. The purpose of the dipping test is to test the degree of adhesion between the fabric and the clay, to test whether the different fabrics are easy to demould after dipping, and the molding ability of different fabrics. Analyze the plasticity, cracks, and adhesiveness of both in the test.

Lessons learned ● ● ● ●

Long manufacturing cycle Easy to crack on the surface Unable to be put into the kiln Hybrid fabric exhibits special quality when pre-formed, but pre-forming process makes it hard to exhibit elasticity difference during later processes

Dipping test with individual fabric Ripstop

Thin Fusing

Muslin

Lycra

First time dipping into clay

When first immersed in the clay, materials combine well with the clay. Similarly, we can see that ripstop and thin fusion can maintain the original shape well, while muslin and lycra are easily deformed due to their water absorption. The continuing test is that we stitch one elastic material and one non-elastic material together to see if hybrid fabric formwork would help with featured geometry. After first dipping, there’s no significant effect, and after applying several layers, it became easy to crack. And we will run some tests like extruding test on hybrid fabric and without pre-stretching the fabric base on the dipping test.

Final outcome

Plasticity

Easy to shape

Difficult

Crackness

Easy to crack

Small crack on the surface

Adhesiveness

Easy to attach at the beginning, when it getting thicker, it is easy to fall of

Easy to attach

Small cracks on the surface Easy to attach

A lot of cracks on the surface Easy to attach

After dipping for the first layer, there’s no significant effect, so apply several layers after that by brush, but still easy to crack Pre-forming process affects its elasticity when dipping, further tests need to be done without pre-stretching to see if this method can help with featured geometry

Experiments by Shu Xiao

POTENTIAL: Flexibility of the fabric aids in form-ﬁnding.

RESEARCH WORKFLOW Thesis - Final Major Project

DRAWBACK: Optimising the tensioning system sturdiness.

FABRIC

CERAMICS INDUSTRY & CHALLENGES CERAMICS INDUSTRY & CHALLENGES 01

LOW-TECH, DEVELOPING ECONOMIES LOW-WITH TECH,EMERGENCY DEVELOPINGNEEDS, ECONOMIES WITH EMERGENCY NEEDS, RESEARCH QUESTION BUT WITH RICH CERAMIC-CRAFT BUT HISTORY WITH&RICH LOCAL CERAMICAVAILABILITY CRAFT OF HISTORY MATERIALS. & LOCAL AVAILABILITY MATERIALS. 02OF research project aim intent PRODUCTION OF PERFORMATIVE CERAMIC PROBLEM SPACE SHELL ASSEMBLIES: Stereotomic panels made Gap between production labour shortage Gap between usingSkilled microvariations in afor single reusable mouldproduction

PROBLEM SPACE Skilled labour shortage for craft-based production R&D in high-tech systems

timeline & Design Management craft-based production

R&D in highHaphazard material management tech cycle: systems

Haphazard material

timeline & Design Management

The need for optimised design-tomanagement cycle: production workﬂows

SOLUTION SPACE

1. For manufacturers: Unscrupulous consumption 1.of For nonmanufacturers: Unscrupulous consumption of nonrecyclable materials: Formwork waste generationrecyclable in materials: Formwork waste generation in conventional production. conventional production.

How can digital encoding of fabric The need to balance between low tech tensioning The need to balance between low tech formwork and physical The need and for high tech fabrication resources resources and high tech fabrication system aidSOLUTION in variable casting of optimised solutions (craft vs technology). solutions (craft vs technology). design-tostereotomic ceramic assemblies?? SPACE production workﬂows

How can robotic positioning of fabric formwork aid in ceramic agility and performance to enThe role of Automation RESEARCH: The role of Automation sure sustainable lifecycle patterns? STATEOF-THE-material ART

2. For designers: Conventional prototyping processes 2. Forleading designers: Conventional prototyping processes leading to poorly crafted and material-optimised products toand poorly crafted and material-optimised products and RESEARCH: compromise in product's performance. compromise in product's performance.

SOLUTION SPACE

/intelligence in determining the design /intelligence in determining the design space for manufacturers and testingspace for manufacturers and testing prototypesSOLUTION for designers. prototypes for designers. SPACE

LOCAL CONTEXT & CERAMIC LOCAL STAKEHOLDERS CONTEXT & CERAMIC STAKEHOLDERS 1. GEOMETRY: Discretisation of shell geometries into developable stereotomic panels. SUGGESTED DEVELOPMENTS: SUGGESTED DEVELOPMENTS: CURRENT ISSUES: CURRENT ISSUES: - Prototyping Designers -POTENTIAL Prototyping SOLUTIONS: tool: Adaptive POTENTIAL SOLUTIONS: Designers - multiple moulds and Designers -Designers multiple moulds and tool: Adaptive 2. FORMWORK: Efficient fabric knitting Designer Use of robotic actuation and Designer - Use of robotic actuation and that help in testing physical methods that help in testing prototypes required to test geometricprototypes physical requiredmethods to test geometric and stitching as per the panel geometry. their physical intelligence their physical intelligence for optimised performance of geometries before performance of geometries before for optimised performance leading to unscrupulousperformance leading to unscrupulous 3. TENSIONING: Automated physical tooling to design. design. ceramic production. ceramic production. consumption of material. consumption of material. micro-adjust re-usable mould for every panel. - Use of Tool fabric formworks Manufacturer - Use of fabric formworks Manufacturer - Design & Analysis Tool Manufacturer - Design & Analysis Manufacturer - dependence on Manufacturer - dependence on 4. MANUFACTURE: Additive Manufacturer manufacture and their digital intelligence for and their digital intelligence for Analytic methods that optimise Analytic digital methods that optimise conventional design methods that are conventional designdigital methods that are of the panels over the tensioned formwork. production. optimised production. toolingintrinsic based on the geometry the tooling optimised based on the geometry not ceramic material-intrinsic leadingnot to ceramicthe materialleading to 5. ASSEMBLY: Simple manual assembly of before ceramic production. before ceramic production. conventional wasteful moulds. conventional wasteful moulds. panels using stay-in-place fabric formwork.

problems

objectives

solutions

POTENTIAL: Lightweight and low density + agility by its plasticity, gravity and machine behaviour. DRAWBACK: Structural stability

CLAY

DESIGN STATEMENT

Aspects of the research project

ASPECTS OF THE RESEARCH PROJECT

questions: addressing the parameters

Why fabric formwork? Which fabric? What is their architectural value? Why and how robotic actuation? What are the limits of tensioning? Which ceramic manufacturing process? What is the performative goal? How do the materials behave together? What is the design output? What forms of geometries to be developed? How do these help the designer/fabricator?

variable 01: manufacturer - Intelligent Fabric Formwork 1. Fabric formwork: Interaction of clay's plasticity and fabric's flexibility - aids in lightweight, reduces waste, complex nonstandard geometry, informed structure (over others like milled/cut/adaptive/3d printed/stay-in-place formwork) 2. Inflated/cable guided fabrics: Guides in structural efficiency of weak materials like clay with integrated tension - large span shell structures/hybrid structural skin (over others like draped/splines/tensioned in frame) 3. Knitted fabrics: Scope for 'architectural' needs - 3D shaping with minimal stitching, multilayers, openings, surface textures, cavities, inherent elasticity for large curvatures.

constants: Design for Manufacture process 1. Ceramic manufacturing process: Variable casting solid/hollow complex geometries (one that overcomes the need for multiple moulds due to subtractive process) 2. Performative goal: Self-supporting shell ceramic assemblies. 3. Design Output: 1:100 section of a deployable lightweight earthquake resistant structure in a low-tech economy (Eg: Optimised thin tiled shell structures in clay-rich Africa are not quake resistant) 4. Geometries: Stereotomic ceramic panels via additive ceramic manufacturing methods.

variable 02: designer - Intelligent Tensioning System 1. Robotic actuation: Given the complex forms, and the resistance exerted by the flexible fabric, multi-axes varying of imposed forces help in the optimisation of its structural intelligence (resist forces in pure tension) and to adjust tolerances for form-finding prototyping studies. 2. Bending active tensioning: Its high flexural capacity of the aids to produce significant curvatures using slender elements without yielding. Variable restraining at the boundaries is necessary for defining stereotomic geometries. Moreover, it needs motion freedom that produces a trajectory for the formwork to move it from its start to the rest position.

RESEARCH DIAGRAM Fit into the state of the art

KnitCandela

Straitus Bridge

Smart Dynamic Casting

formwork actuation PERFORMANCE OF CONCRETE STAY-IN-PLACE FORMWORK

ADDITIVE MANUFACTURE FORMWORK WASTE

unsustainable & unbalanced material lifecycle

behaviour of composite materials

poor designer-manufacturer dynamics

RESEARCH PROJECT

intelligence of fabric’s flexibility + clay’s plasticity

Mark West

multi-axis 3D printing

RE-USABLE FORMWORK AUTOMATED ACTUATION

resource consumption of formwork systems

structural performance of ceramics Armadillo Vault

flexibility of forms

WASTE GENERATION CONVENTIONAL SYSTEMS

the need for quake-resistant doubly curved ceramic shells

Prototype Testing

Ceramic Industry

Mapungudwe Brick Shell

+ apply stereotomy to ceramic assemblies

PERFORMANCE OF FABRIC TENSIONING SYSTEMS

BEHAVIOUR OF CLAY+FABRIC CONSTRAINED FORMS

STEREOTOMIC GEOMETRY

PERFORMANCE OF CERAMICS POOR QUAKE RESISTANCE

RESEARCH PLAN

Thesis - Final Major Project

APRIL 25th to NOVEMBER 03rd DIGITAL STUDIES

DESIGN OF THE GEOMETRY STEP 01 (Apr 25th - May 13th)

WEEK 17 WEEK 18 WEEK 19

1. Shell structure design development 2. Discretisation by Thrust Network Analysis 3. Fabric Formwork Pattern Generation

REVIEW (May 17th)

project delivery phase 01

PHYSICAL STUDIES

FORMWORK TENSIONING

WEEK 20 WEEK 21 WEEK 22

1. Tensioning system development 2. Robotic Fabrication System 3. Fabric Stitching and setup 4. Interim Presentation

TESTING PHASE 1. ROBO-ACTUATION TESTING 2. OPTIMISATION OF DIGITAL GEOMETRY

STEP 03 (June 13th - June 26th)

WEEK 23

project delivery phase 02

FABRICATION SETUP

testing phase

REVIEW (June 09th)

PROGRESS CHECK (June 30th)

PRODUCTION PHASE 01 STEP 04 (July 04th - July 24th)

ADDITIVE MANUFACTURE

PRODUCTION PHASE 02 STEP 05 (July 25th - Aug 14th)

CERAMIC PANEL ADDITIVE MANUFACTURING

project delivery mid-phase 03 PIN-UP (Aug 17th)

ASSEMBLY PHASE STEP 06 (Aug 20th - Oct 09th)

SHELL ASSEMBLY

STEREOTOMIC ASSEMBLY OF THE CERAMIC PANELS

STEP 07 (Oct 10th - Oct 23rd)

DOCUMENTATION

STEP 08 (Oct 24th - Nov 03rd)

SUBMISSION

project delivery phase 03 draft portfolio submission

final portfolio submission

BIBLIOGRAPHY Initial Projects Module

[1] Andreani, Stefano, Jose Luis Garcia del Castillo, Aurgho Jyoti, Nathan King, and Martin Bechthold. “Flowing Matter: Robotic Fabrication of Complex Ceramic Systems.” Eindhoven, The Netherlands, 2012. https://doi.org/10.22260/ISARC2012/0071. [2] BLOCK, PHILIPPE, MATTHIAS RIPPMANN, and TOM VAN MELE. “THE ARMADILLO VA U LTBALANCING COMPUTATION AND TRADITIONAL CRAFT.” In FABRICATE 2017, n.d. [3] Bradley, R A, and M Gohnert. “Three Lessons from the Ma-pungubwe Shells.” South African Institution of Civil Engineering 58, no. 3 (2016): 2–12. https://doi. org/10.17159/2309-8775/2016/v58n3a1. [4] Fallacara, Giuseppe, Claudio D’Amato, Marco Stigliano, and Richard A. Etlin. Stereotomy: Stone Architecture and New Re-search. Paris: Presses des Ponts, 2012. [5] International Conference on Flexible Formwork, Antony Darby, Mark Evernden, Tim Ibell, and John Orr, eds. Second In-ternational Conference on Flexible Formwork: Icff2012 : Full Papers, 2012. [6] “Knitting for Architecture” | Guest Lecture by Dr. Mariana Popescu | Harvard GSD6338. Accessed April 21, 2022. https://www.youtube.com/watch?v=RzN4c7lsFxk. [7] Labonnote, Nathalie, Anders Rønnquist, Bendik Manum, and Petra Rüther. “Additive Construction: State-of-the-Art, Chal-lenges and Opportunities.” Automation in Construction 72 (De-cember 2016): 347–66. https://doi.org/10.1016/j. autcon.2016.08.026. [8] Lloret-Fritschi, Ena, Timothy Wangler, Lukas Gebhard, Jaime Mata-Falcón, Sara Mantellato, Fabio Scotto, Joris Burger, et al. “From Smart Dynamic Casting to a Growing Family of Digital Casting Systems.” Cement and Concrete Research 134 (August 2020): 106071. https://doi.org/10.1016/j.cemconres.2020.106071.

[9] Popescu, M., L. Reiter, A. Liew, T. Van Mele, R.J. Flatt, and P. Block. “Building in Concrete with an Ultra-Lightweight Knitted Stay-in-Place Formwork: Prototype of a Concrete Shell Bridge.” Structures 14 (June 2018): 322–32. https://doi.org/10.1016/j. istruc.2018.03.001. [10] POPESCU, MARIANA , MATTHIAS RIPPMANN, PHILIPPE BLOCK, and TOM VAN MELE. “KNITCANDELACHALLENGING THE CONSTRUCTION, LOGISTICS, WASTE AND ECONOMY OF CONCRETE-SHELL FORMWORKS.” In FABRICATE 2020, n.d. [11] Reimagining Shell Structures - Philippe Block. Accessed April 21, 2022. https:// www.youtube.com/watch?v=vAavRx7uoeA. [12] Rippmann, Matthias, and Philippe Block. “Computational Tessellation of Freeform, Cut-Stone Vaults.” Nexus Network Journal 20, no. 3 (December 2018): 545–66. https://doi.org/10.1007/s00004-018-0383-y. [13] Sheil, Bob, Mette Ramsgaard Thomsen, Martin Tamke, and Sean Hanna, eds. Design Transactions: Rethinking Information Modelling for a New Material Age. London: UCL Press, 2020. [14] West, Mark. The Fabric Formwork Book: Methods for Building New Architectural and Structural Forms in Concrete. London ; New York: Routledge, 2017. [15] Yang, Xuyou, Paul Loh, and David Leggett. “Robotic Variable Fabric Formwork.” Journal of Computational Design and Engineering 6, no. 3 (July 1, 2019): 404–13. https://doi.org/10.1016/j.jcde.2018.10.001. [16] YUAN, PHILIP, ACHIIM MENGES, and NEIL LEACH. DIGITAL FABRICATION, n.d.

2021/22

BARC0059: Initial Projects STUDENT NO. 20111292