M.Arch_Design for Manufacture_Term 03 by Harsh Shah

robotic wirecutting

CLAY-CERAMIC BEHAVIOUR Current manufacturing systems

The implementation of variable ruled surfaces at the seams between units provides increased shear resistance like bonding between Catalan vault tiles.

To address performative aspects of an evaporative screen, extrusions of clay were wirecut to define the varying forms.

To tap onto the plasticity of clay to create complex forms ruled shaped interlocking units using spatial discretization. Differentiated non-uniform patterned cuts and apertures.

1. Waterjet was done to mitigate differential shrinkage but max achievability was 45 deg. 2. Planar geometry used on the top-base surfaces to lay tiles flat for ease of production.

1. Issues with cutting speed challenging the softness of clay. 2. Manual assistance needed with robot to ensure stability during the fabrication process.

1. Custom workpiece for supporting clay during the process and to accommodate for undercuts. 2. Additional testing needed for tolerance - shrinkage, controlled firing and drying, and clay body specifications.

robotic wirecutting

USES - PROS & CONS

Tool development and quick testing

INDUSTRIAL USES

COMPLEX FORMWORK

LESS PRODUCTION TIME - NO ROUGH TOOLING SMOOTHER SURFACE FINISH ONLY RULED SURFACES

SLAB BASED APPROACH more flexibility in shaping - the aggregation can more accurately approximate a free-form surface. wire types - kerfs, segments, wire sawing

FIRST TEST CUTS

more flexible tooling wire geometry tensioning system extendability

toolpath strategy volume envelope

surface friction geometry deformation

cutting speed positive and negative geometry

clay compostion clay state post processing

robotic wirecutting

PARAMETERS & EVALUATION Tool development and quick testing

MOISTURE & GROG CONTENT ADHESION LEVEL VARIABLE MATERIALITY

RULED GEOMETRIES (FORM) TEXTURED COMPONENTS

material

high grog content, high green strength and low shrinkage works better. how difficult the cut part is to remove from the stock? how does the clay composition affect the stability and cut?

geometry

are ruled surfaces a limitation for the process? does discretization and local approvimation aid in cutting freeform geometries? rough milling or detailing of textures possible?

RATIONALISING FREEFORM

SIZE AND EXTENSION PRECISION & TOLERANCE

tool

SURFACE QUALITY

CUTTING SPEED VARIABLE TOOLPATH SOFTWARE

process

tool size restrictions wrt working volume and geometry precision in movement and volume removed at locations (conic vertices, sharp angles, etc) smoothness finish and consistency for assembly, especially stereotomy?

cutting speed and orientation for optimisation changing toolpaths for internal vs external cuts, deep/shallow cuts, etc optimisation software like PyRAPID that clusters similar toolpaths within the geometry and computes inverse kinematics.

robotic wirecutting

GEOMETRIC TESTS

Tool development and quick testing

study surface finish workholding strategies clay behaviour

testing curve tolerances testing complex surface cuts

study adhesion behaviour ruled surface changes change speed as per geometry

3DP + wirecut

check edge behaviour slab cutting from block

slumpcast + wirecut

extrusions + wirecut

minimal surfaces

STATE-OF-THE-ART

FREE-FORM (non-ruled) SURFACE GEOMETRY WIRECUTTING

robotic wirecutting

STATE-OF-THE-ART

PREVENT GEOMETRIC DISTORTION THROUGH ROWC

robotic wirecutting

STATE-OF-THE-ART

SPATIAL WIRE CUTTING - CONTROL CURVATURE

robotic wirecutting

STATE-OF-THE-ART

WIRECUTTING DOUBLE CURVED MINIMAL SURFACES

robotic wirecutting

MINIMAL SURFACES

robotic wirecutting

FIRST TESTS Testing toolpaths

LINEAR SWEEPING MOTION Important to test with suitable clay with less friction

ZIG-ZAG SAW LIKE MOTION Speed tests and static workholding is critical in this.

No difference observed in a planar cut. Yet to test on the given block geometry

robotic wirecutting

BASIC CUTS

Geometries & parameters

PLANAR CONTOUR CUT The need to understand cuts with different clay behaviour

SINGLY CURVED SURFACE

SPLINE EDGED SURFACE

Different testing toolpaths to study surface tolerance

How can the edge conditions be honed with the tool?

DOUBLY CURVED SURFACE Can speeds and movement vary as curvature analysis?

BASIC CUTS

Geometries & parameters

robotic wirecutting

CATALOGUE

Clay material variables

robotic wirecutting

PATHWAYS

Further directions

STRUCTURE - Developing shell geometries

TOOL - Actuating formwork for fabric 3DP

PROCESSES - To manufacture complex forms

wirecutting as surface finish

PATHWAYS

Further directions

strength

formwork

waste 01 DESIGN OF AN OPTIMISED STRUCTURAL SHELL

02 ROBOTIC WIRECUT THE 3DP INDIVIDUAL PANELS

hybrid DFMA production fresh clay leather hard fired clay

3DP - for detailing, developing variable geometry Wirecut - stereotomic finish, avoid deformation Fabric formwork - Flexibility & ease in assembly

digital tool

physical tool

Doubly curved panels of variable thickness and ribbed stiffeners designed through structural optimisation, developed through 3DP+wirecut and that are assembled based on stereotomy with aid of fabric scaffolding. PRODUCTION: Material Sustainability, Less waste, Variable geometries POST-PROCESSING: Time saving, avoid geometry deformation, workhold ASSEMBLY: Geometric Freedom, lightweight, portable, flatpack.

03 FABRIC FORMWORK ASSEMBLY

wirecutting for moulds

PATHWAYS

Further directions

topologically optimised geometries

To cast topologically optimised building components using wirecut ceramic formwork and computatinal tools (by rationalising freeform geometry to ruled developable surfaces) DESIGN: Structurally optimised concrete/ceramic geometry. PRE-PRODUCTION: Robocut ceramic formwork that is fired. PRODUCTION: Casting concrete/clay within the cut-moulds.

strength

formwork

waste

digital-physical feedback

robotic fab workflow

wirecutting for formwork

PATHWAYS

Further directions

minimal freeform surfaces

To design and compute positive geometries for casting, rationalising to ruled strips for fabric formwork and negative geometries as moulds for wire cut clay.

strength

To cast thin shell minimal surfaces in clay/concrete using internal support as fabric formwork and external moulding as wirecut ceramics.

formwork

waste

DESIGN: Minimal surface complex forms PRE-PRODUCTION: Robocut ceramic formwork and fabric strip morphologies PRODUCTION: Solid casting of ceramic/concrete thin shelled forms.

digital-physical feedback

computational workflow

RESEARCH DESCRIPTION

Final Thesis Report

CERAMICS INDUSTRY & CHALLENGES AUTOMAINTELLIGENCE TION, AI, AND ARCHITEAND CLOWTURE ARCHITECTURE AUTOMATION, ARTIFICIAL TECH, DEVELOPING ECONOMIES WITH EMERGENCY NEEDS,

BUT WITH RICH CERAMIC-CRAFT HISTORY & LOCAL AVAILABILITY OF MATERIALS. The major project seeks to develop variable shell geometries through hybrid manufacturing PROBLEM SPACE workflows and circular design principles. Multipurpose, adaptable, and reconfigurable tools Skilled labour shortage for Gap between production like parametric design and robotic fabrication are major driving forces. However, the key craftbased production timeline & Design Management assessment relies on the “high volume-mass customised” production approach which is in-turn dependent on the material behaviour and the architectural geometry. R&D in high-tech Haphazard material management cycle: The thesis shall test the efficiency of the data-driven design and its impact on the customisable systems

The need for optimised design-toproduction workﬂows

SOLUTION SPACE

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

automated tool and vice-versa. For the physical tool, how does it change its stereotypical image 1. For manufacturers: Unscrupulous consumption of nonof performing repetitive and precise actions to flexible, versatile, and informed interventions? The Economics of ‘Digital Making’, Mario Carpo DFMA Workflow for the developing context recyclable materials: Formwork waste generation in Similarly, the data analytic aspect of the digital tool for performative applications seeks conventional production. stronger validation. In parallel, the project seeks to optimise the technical processes of clay 3D printing, fabric formwork and wire cutting. Thus, the thesis shall intend to question the 2. For designers: Conventional prototyping processes leading potential of an integrated manufacturing platform, given the hybrid techniques explored. to poorly crafted and material-optimised products and RESEARCH: The role of Automation compromise in product's performance.

SOLUTION SPACE

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

STAKEHOLDERS

Through the process, the aim is to question and adapt the methodologies CURRENT ISSUES: in accordance with the context it addresses. For example, how to standardise the use the robotmoulds or developand novel Designers -ofmultiple DIY high-end tools in the manufacturing process - at the factory and at the site, alongside digital prototypes required to test geometric and analogue craftsmen in low-tech economies? Can DIY-make clay 3D printers support the leading to unscrupulous local craftsmen? How can remote robotic fabricationperformance and collaboration for designers? Can we consumption of material. develop free-hand digitally controlled tools for unskilled labour? etc through cases.

SUGGESTED The DEVELOPMENTS: use of intelligence to balance automation versus labour availability in the AEC industry, Gilles Retsin Designers - Prototyping tool: Adaptive POTENTIAL SOLUTIONS: Designer - Use of robotic actuation and physical methods that help in testing their physical intelligence for optimised performance of geometries before design. ceramic production.

Lastly, the thesis shall reiterate the question from the Contextual- dependence Theory moduleon - can Manufacturer ‘intelligent’ mechanization of craft add social value to technology to develop comprehensive conventional design methods that are architectural design solutions? Especially in challenging socio-economic contexts, there is a not ceramic materialintrinsic leading to need to strike a balance between low-tech resources, craft versus high-tech fabrication moulds. solutions, technology. How can the collaborationconventional of data-drivenwasteful design and automated fabrication be made cost-effective, accessible, and sustainable? “How can artificial intelligence help make robots cheaper without limiting their abilities, in a challenging context?”

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

The human and the Machine

2021/22

STUDENT NO. 20111292

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

Multi-fabrication platform

PROJECT PROPOSAL

BARC0060: Final Major Project

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.

this is what the world needs!

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

how can DFM provide that?

solution space

DFM & AEC INDUSTRY

Solving issues with ‘architectural ceramics’

4PROBLEMS

Extraction & Waste (unbalanced material lifecycle)

High tech manufacture (fueled economic recovery)

4SOLUTION

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

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

4INTENTS

IMPROVING PERFORMANCE

____Alternating Building Material

MANAGING RESOURCE CONSUMPTION ____Efficient Manufacturing Process

MINIMISING WASTE GENERATION

____Strength through geometry

STREAMLINING DFM WORKFLOWS

____Supply Chain development tooling

ANALYSIS Performance

// // // //

Material Strategies Structural optimisation Economic/social Value Technological Innovation

this is what the world needs!

DFM invests in ‘digital making’

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

overall agenda

tool at hand

is the tool efficient enough?

digital and physical tool

RESEARCH DESCRIPTION Final Thesis Report

AUTOMAINTELLIGENCE TION, AI, AND ARCHITEAND CTURE ARCHITECTURE AUTOMATION, ARTIFICIAL The major project seeks to develop variable shell geometries through hybrid manufacturing workflows and circular design principles. Multipurpose, adaptable, and reconfigurable tools like parametric design and robotic fabrication are major driving forces. However, the key assessment relies on the “high volume-mass customised” production approach which is in-turn dependent on the material behaviour and the architectural geometry. The thesis shall test the efficiency of the data-driven design and its impact on the customisable automated tool and vice-versa. For the physical tool, how does it change its stereotypical image of performing repetitive and precise actions to flexible, versatile, and informed interventions? Similarly, the data analytic aspect of the digital tool for performative applications seeks stronger validation. In parallel, the project seeks to optimise the technical processes of clay 3D printing, fabric formwork and wire cutting. Thus, the thesis shall intend to question the potential of an integrated manufacturing platform, given the hybrid techniques explored.

The Economics of ‘Digital Making’, Mario Carpo

Do we still need ‘Mass Production’, Mario Carpo

Beyond the technical assessment that focuses on the tectonics of the tools and processes, with in-depth focus on robotics, the thesis seeks a value assessment of these realms of ‘digital making’ to aid the stakeholders of the AEC industry. To provide social, economic, and performative value by contextualising these applications in developing economies that are rich in handmade craft, local material, and cheap labour availability, like India, the thesis shall next, need to question and reflect on the feasibility of these physical and digital tools, through pragmatic interrogations at every step. Through the process, the aim is to question and adapt the methodologies in accordance with the context it addresses. For example, how to standardise the use of the robot or develop novel DIY high-end tools in the manufacturing process - at the factory and at the site, alongside digital and analogue craftsmen in low-tech economies? Can DIY-make clay 3D printers support the local craftsmen? How can remote robotic fabrication and collaboration for designers? Can we develop free-hand digitally controlled tools for unskilled labour? etc through cases.

The use of intelligence to balance automation versus labour availability in the AEC industry, Gilles Retsin

Lastly, the thesis shall reiterate the question from the Contextual Theory module - can ‘intelligent’ mechanization of craft add social value to technology to develop comprehensive architectural design solutions? Especially in challenging socio-economic contexts, there is a need to strike a balance between low-tech resources, craft versus high-tech fabrication solutions, technology. How can the collaboration of data-driven design and automated fabrication be made cost-effective, accessible, and sustainable? “How can artificial intelligence help make robots cheaper without limiting their abilities, in a challenging context?” The human and the Machine

Multi-fabrication platform

this is what the world needs!

DFM invests in ‘digital making’

Data-driven design & fabrication

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

‘Automation, AI & Architecture’ - collaboration of data-driven design and automated fabrication in the digital age.

overall agenda

tool at hand

collaborators

what does the industry want?

R&D in high-tech systems

Haphazard material management cycle:

CERAMIC INDUSTRY & CHALLENGES 1. For manufacturers: Unscrupulous consumption of nonStakeholdersrecyclable perspective - Formwork Designers & generation Manufacturers materials: waste in

The need for optimised design-toproduction workﬂows

SOLUTION SPACE

resources and high tech fabrication solutions (craft vs technology).

what does the industry want?

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

SOLUTION SPACE

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

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

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

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

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

Limited labour and resources for bespoke craft.

Research for decorative rather than architectural!

POTENTIAL SOLUTIONS: Designer - Use of robotic actuation and their physical intelligence for optimised design. Manufacturer - Use of fabric formworks and their digital intelligence for optimised production.

Finishing and precision dependent on manual labour

Conventional wasteful subtractive moulding methods

Profit driven market for conventional products

Intensive technology focus only for mass production

Superflous unsustainable material consumption

Restricted R&D in high tech manufacturing tools

this is what the world needs!

DFM invests in ‘digital making’

Data-driven design & fabrication

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

‘Automation, AI & Architecture’ - collaboration of data-driven design and automated fabrication in the digital age.

overall agenda

tool at hand

collaborators

who is the context?

Automation & Intelligence

‘High-volume mass customised production’ - address technological constriants for the manufacturers and the designers.

ceramic industry

low-tech resources

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

Gap between production timeline & Design Management

Haphazard material management cycle: 1. For manufacturers: Unscrupulous consumption of nonrecyclable materials: Formwork waste generation in conventional production.

The need for optimised design-toproduction workﬂows

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

SOLUTION SPACE

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

SOLUTION SPACE

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

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

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

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

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

LOCAL MATERIAL AVAILABILITY

TRADITIONAL CONSTRUCTION

SKILLED CRAFTSMAN

CHEAP LABOUR

this is what the world needs!

DFM invests in ‘digital making’

Data-driven design & fabrication

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

‘Automation, AI & Architecture’ - collaboration of data-driven design and automated fabrication in the digital age.

overall agenda

tool at hand

collaborators

Low-tech economies

‘rich in local resources - material and labour’ - bridge the gap between craft and technology to address emergency issues.

the context

what does the material want?

Automation & Intelligence

‘High-volume mass customised production’ - address technological constriants for the manufacturers and the designers.

ceramic industry

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

concern - FABRICATION ?

REINFORCEMENT Material Behaviour

the need for alternative material

COMPARISON

ADDITIVE MANUFACTURING

ASSEMBLY & DISTRIBUTION

FABRIC FORM-FINDING

Tools and Processes

Fired vs Unfired Clay

Tools and Processes

the need to optimise fabrication

EFFICIENCY OF FIBRES OVER CAGES

concern - ASSEMBLY?

INCREASE DURABILITY

the need to simplify assembly

MORE STRUCTURAL STRENGTH

the need to manage construction

STRONGER BONDING

EXPERIMENTS - CLAY FORMULATION, COMPOSITE & FIBRE REINFORCEMENT

PROJECT PROJECT OBJECTIVES OBJECTIVES

Explore clay rheology and properties, Developing material by combining clay and glass. Assessing fibre reinforcement material options

//Clay formulation

//Testing material behaviour in terms of strength and translucency with different glass infusions.

scoping trials

//Extrusion & Fibre Reinforcement

//Clay & Glass composite

// Understanding workability, durability and plasticity of various combinations of clay and additives

Tests to Further Address the Project Aim

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

ould be lost due an increase thetomass/ thickness of application) by developing a ceramic-glass composite and having it in ceramics (as to it could be lostindue an increase in the mass/ thickness of application) by developing a ceramic-glass composite and having it

optimization.

drying time - rapid plasticity - low workability

eialused as raw material Glass frit fibre/ roving+ Glass + Glass stringers Glass (coarse) fibre/ roving Testing out workability of mix Requires plasticizer

+ Glass beads

+ Glass pieces

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

+ transmission Glass pieces Light test Planar - high Extrusions - minimal

Analysing deformations

Before firing

er water %

te after firing

lass fibres - fails to adhere onto clay; influences geometry underweight mix 1 – experimental firing to nslucency Glass fibres - fails to adhere onto clay; influences geometry observe responseunderweight of fibres to cracks

After firing

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

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

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

Research by Calwin Kwan and Monisha Sridhara clay slip & glass fibre mesh - test out different densities of fibre strands, their ability to fuse & possible light transmission

this is what the world needs!

DFM invests in ‘digital making’

Data-driven design & fabrication

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

‘Automation, AI & Architecture’ - collaboration of data-driven design and automated fabrication in the digital age.

overall agenda

tool at hand

collaborators

Low-tech economies

follow material behaviour

‘rich in local resources - material and labour’ - bridge the gap between craft and technology to address emergency issues.

‘clay - embrace my plasticity, reduce my carbon footprint’ - the re-defination of ‘performance’ in the fabrication process.

the context

local material

evaluate the state-of-the-art

Automation & Intelligence

‘High-volume mass customised production’ - address technological constriants for the manufacturers and the designers.

ceramic industry

case studies

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

this is what the world needs!

DFM invests in ‘digital making’

Data-driven design & fabrication

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

‘Automation, AI & Architecture’ - collaboration of data-driven design and automated fabrication in the digital age.

overall agenda

tool at hand

collaborators

Low-tech economies

follow material behaviour

address ‘performance’ of ceramics

‘rich in local resources - material and labour’ - bridge the gap between craft and technology to address emergency issues.

‘clay - embrace my plasticity, reduce my carbon footprint’ - the re-defination of ‘performance’ in the fabrication process.

‘how can one design using a weaker material?’ - understanding the interdependencies of a shell structure.

the context

local material

state-of-the-art

now, defining the research intent?

Automation & Intelligence

‘High-volume mass customised production’ - address technological constriants for the manufacturers and the designers.

ceramic industry

DFMA process

RESEARCH INTENT

Defining the research question

strength

formwork

project aim

PRODUCTION OF PERFORMATIVE CERAMIC SHELL ASSEMBLIES: Stereotomic panels made using multi-fabrication robotic platform.

waste

CONVENTIONAL BUILDING ELEMENT

research intent

hybrid DFMA production How can efficient digital fabrication platforms aid in ceramic agility and performance to ensure sustainable material lifecycle patterns?

OPTIMISED BUILDING ELEMENT

this is what the world needs!

DFM invests in ‘digital making’

Data-driven design & fabrication

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

‘Automation, AI & Architecture’ - collaboration of data-driven design and automated fabrication in the digital age.

overall agenda

tool at hand

collaborators

Low-tech economies

follow material behaviour

address ‘performance’ of ceramics

‘rich in local resources - material and labour’ - bridge the gap between craft and technology to address emergency issues.

‘clay - embrace my plasticity, reduce my carbon footprint’ - the re-defination of ‘performance’ in the fabrication process.

‘how can one design using a weaker material?’ - understanding the interdependencies of a shell structure.

the context

local material

state-of-the-art

developing the architectural geometry!!

Automation & Intelligence

‘High-volume mass customised production’ - address technological constriants for the manufacturers and the designers.

ceramic industry

Efficiency of shell structures

‘intelligent fabrication systems’ - hybrid ceramic manufacturing systems simplified through robotic tooling and digital data.

research intent

digital tool

DESIGN OF THE SHELL STRUCTURE Design, Analysis, Optimise and Discretisation

proposed prototype

geometry generation

structural optimisation

thrust network analysis & discrete element analysis 01 Developing small-scale shell systems through RhinoVault as per physical parameters. 02 Structural analysis methods to generate rib supports to add tension in the system 03 Optimisation through data-driven analysis to rationalise individual stereotomic geometries

this is what the world needs!

DFM invests in ‘digital making’

Data-driven design & fabrication

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

‘Automation, AI & Architecture’ - collaboration of data-driven design and automated fabrication in the digital age.

overall agenda

tool at hand

collaborators

Low-tech economies

follow material behaviour

address ‘performance’ of ceramics

‘rich in local resources - material and labour’ - bridge the gap between craft and technology to address emergency issues.

‘clay - embrace my plasticity, reduce my carbon footprint’ - the re-defination of ‘performance’ in the fabrication process.

‘how can one design using a weaker material?’ - understanding the interdependencies of a shell structure.

the context

local material

Automation & Intelligence

‘High-volume mass customised production’ - address technological constriants for the manufacturers and the designers.

ceramic industry

Efficiency of shell structures

‘intelligent fabrication systems’ - hybrid ceramic manufacturing systems simplified through robotic tooling and digital data.

state-of-the-art

digital tooling and analysis

‘computational design to constructional integration’ - discretising and rationalising ceramic geometries from global form.

architectural geometry

what are the challenges of the fabrication processes?

research intent

option 01

VARIABLE PANELS - ADDITIVE MANUFACTURING Option 01 - Non Planar 3DP on scaffold structure

robotic toolpath scaffolds production time

Use of lattice spanning features as reinforcement

workholding layer adhesion drying behaviour Irregular variation of extrusion deposition along toolpath

Double thickness-offset toolpath to support complex forms

LIMITATIONS

VARIOUS

3DP

METHODS

THE FEED SPEED AND EXTRUSION SPEED:

01 Overhanging Geometry: How can the ‘pseudoplas-

03 A controlled overflow across various points of the

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

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

THE ROLE OF SCAFFOLDS AND SUPPORTS:

04 How can the potential for geometric and tex-

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

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

THE

GEOMETRY

AND

RESOLUTION:

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

G-CODE ARTICULATION FOR MATERIAL CONTROL & MOVEMENT:

05 How can the flow-rate and the extrusion values be mod-

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

fresh clay 3DP - for detailing, developing variable geometry

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

option 02

VARIABLE PANELS - ADDITIVE MANUFACTURING

Option 02 - 3DP + Robotic Wire Cutting

more flexible tooling wire geometry tensioning system extendability

toolpath strategy volume envelope

MOISTURE & GROG CONTENT

planar 3D Printing

ADHESION LEVEL

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.

surface friction geometry deformation

material

geometry

are ruled surfaces a limitation for the process? does discretization and local approvimation aid in cutting freeform geometries? rough milling or detailing of textures possible?

RULED GEOMETRIES (FORM) RATIONALISING FREEFORM SIZE AND EXTENSION PRECISION & TOLERANCE

tool

SURFACE QUALITY

robotic hotwire cutting

FIRST TEST CUTS

CUTTING SPEED VARIABLE TOOLPATH SOFTWARE

clay compostion clay state post processing

high grog content, high green strength and low shrinkage works better. how difficult the cut part is to remove from the stock? how does the clay composition affect the stability and cut?

VARIABLE MATERIALITY

TEXTURED COMPONENTS

cutting speed positive and negative geometry

process

robotic hotwire cutting

FURTHER TESTS

PREVENT GEOMETRIC DISTORTION THROUGH ROWC

Important to test with suitable clay with less friction

LINEAR SWEEPING MOTION

Speed tests and static workholding is critical in this.

ZIG-ZAG SAW LIKE MOTION

1. Issues with cutting speed challenging the softness of clay. 2. Manual assistance needed with robot to ensure stability during the fabrication process. 3. Custom workpiece for supporting clay during the process and to accommodate for undercuts. 4. Additional testing needed for tolerance - shrinkage, controlled firing and drying, and clay body specifications.

robotic hotwire cutting

FURTHER TESTS

PLANAR CONTOUR CUT The need to understand cuts with different clay behaviour

SINGLY CURVED SURFACE

SPLINE EDGED SURFACE

Different testing toolpaths to study surface tolerance

How can the edge conditions be honed with the tool?

DOUBLY CURVED SURFACE Can speeds and movement vary as curvature analysis?

robotic hotwire cutting

MATERIAL TESTS

robotic hotwire cutting

GEOMETRY TESTS

1. Issues with cutting speed challenging the softness of clay. 2. Manual assistance needed with robot to ensure stability during the fabrication process.

3. Custom workpiece for supporting clay during the process and to accommodate for undercuts. 4. Additional testing needed for tolerance - shrinkage, controlled firing and drying, and clay body specifications.

Important to test with suitable clay with less friction

this is what the world needs!

DFM invests in ‘digital making’

Data-driven design & fabrication

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

‘Automation, AI & Architecture’ - collaboration of data-driven design and automated fabrication in the digital age.

overall agenda

tool at hand

collaborators

‘High-volume mass customised production’ - address technological constriants for the manufacturers and the designers.

ceramic industry

Low-tech economies

follow material behaviour

address ‘performance’ of ceramics

‘rich in local resources - material and labour’ - bridge the gap between craft and technology to address emergency issues.

‘clay - embrace my plasticity, reduce my carbon footprint’ - the re-defination of ‘performance’ in the fabrication process.

‘how can one design using a weaker material?’ - understanding the interdependencies of a shell structure.

the context

local material

digital tooling and analysis

Automation & Intelligence

Efficiency of shell structures

‘intelligent fabrication systems’ - hybrid ceramic manufacturing systems simplified through robotic tooling and digital data.

state-of-the-art

production variability

research intent

production speed

‘computational design to constructional integration’ - discretising and rationalising ceramic geometries from global form.

‘non-planar 3DP vs planar 3DP’ - optimising toolpath for detailed variable discrete geometries with production time in mind

‘efficient end-effector’ - the geometry in leather hard state is wirecut based on its stereotomic position to avoid distortion.

architectural geometry

additive manufacturing

robotic wire-cutting

how can the assembly be addressed?

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

experiments

tensile capacity of formwork membrane complements compressive capacity of reinforced ceramic

ASSEMBLY - FABRIC FORMWORK

Tooling developmentKEYfor testing boundary conditions PARAMETERS:

Physical Form-ﬁnding

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 cla 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

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

Fabric Fabric Fabric Fabric properties properties Fabric properties properties properties

02 Observing the behaviour of dif-

● On muslin ripstop /types woven polypropylene ferent clay/ lycra % /with of fabric ● ●

Muslin

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

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

High degree of elasticity

Ripstop

● ● ●

Fabric properties

● ● ●

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

Set on different angled surfaces (30 / 45 / 60) With vertical and perpendicular extruding angle

It was observed that elastic fabrics have good adhesion. Hence this composite behaviour shall help in stay-inplace formwork. However, the woven Conclusion fabrics does not adhere well, but, the drying uniform forangle the ● is Perpendicular extruding helps clay with evenand extrusion shrinkage/deformation is mini● Different angled surfaces make little difference Lycra Muslinhas / lycra exhibit good adhesion mal. ● This potential forto clay, re-uswhereas ripstop /woven polypropylene are the able demouldable moulds. opposite Woven Polypropylene

3.Material Behaviour

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.

Lower degree of elasticity Waterproof Woven

Able to create more forms Woven fabric Durable

Does not adhere to concrete or casted material

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

2.Woven vs knit fabric - behaviour at various angles of shearing 3.Coated/uncoated textiles - impact on waterproof, permeability, shearing, demould, etc

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 Not elastic Elastic Not elastic Not elastic NotNot elastic NotNot elastic Not elastic elastic Not elastic Not elastic Elastic Elastic Elastic ElasticElastic NotNot elastic Not elastic elastic Not 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

Research by Minran Xue and Harsh Shah

experiments

ASSEMBLY - 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

● ● ●

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

Thin Fusing

Muslin

Lycra

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.

First time dipping into clay

Final outcome

● ● ●

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

Conclusion 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

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.

●

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

Research by Minran Xue, Harsh Shah and Shu Xiao

proposition

ASSEMBLY - FABRIC FORMWORK

Tooling development for testing boundary conditions

The idea to avoid this superfluous scaffolding using flexible fabric formworks casted in clay that is deployable, lightweight and portable

Digital tools to translate these freeform geometries to ruled surfaces.

The shell geometry is rationalised to ruled strips for fabric formwork which are stitched together and set up in place

A case study that converts minimal surface to fabric strip morphologies

this is what the world needs!

DFM invests in ‘digital making’

Data-driven design & fabrication

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

‘Automation, AI & Architecture’ - collaboration of data-driven design and automated fabrication in the digital age.

overall agenda

tool at hand

collaborators

Low-tech economies

follow material behaviour

address ‘performance’ of ceramics

‘rich in local resources - material and labour’ - bridge the gap between craft and technology to address emergency issues.

‘clay - embrace my plasticity, reduce my carbon footprint’ - the re-defination of ‘performance’ in the fabrication process.

‘how can one design using a weaker material?’ - understanding the interdependencies of a shell structure.

the context

local material

digital tooling and analysis

production variability

state-of-the-art

production speed

Automation & Intelligence

‘High-volume mass customised production’ - address technological constriants for the manufacturers and the designers.

ceramic industry

Efficiency of shell structures

‘intelligent fabrication systems’ - hybrid ceramic manufacturing systems simplified through robotic tooling and digital data.

research intent

assembly and disassembly

‘computational design to constructional integration’ - discretising and rationalising ceramic geometries from global form.

‘non-planar 3DP vs planar 3DP’ - optimising toolpath for detailed variable discrete geometries with production time in mind

‘efficient end-effector’ - the geometry in leather hard state is wirecut based on its stereotomic position to avoid distortion.

‘intelligent flexible formworks’ - using digital tooling to translate geometries to physical developable fabrication as scaffold.

architectural geometry

additive manufacturing

robotic wire-cutting

simplified assembly

recap of the process - current state?

PATHWAY

Further directions

strength

formwork

waste 01 DESIGN OF AN OPTIMISED STRUCTURAL SHELL

02 ROBOTIC WIRECUT THE 3DP INDIVIDUAL PANELS

hybrid DFMA production fresh clay leather hard fired clay

3DP - for detailing, developing variable geometry Wirecut - stereotomic finish, avoid deformation Fabric formwork - Flexibility & ease in assembly

digital tool

physical tool

03 FABRIC FORMWORK ASSEMBLY

RESEARCH PLAN

Thesis - Final Major Project

project delivery phase 01

REVIEW (May 17th)

PHYSICAL STUDIES

INITIAL TESTS STEP 01 (May 18th - June 09th)

project delivery phase 02

WEEK 20 WEEK 21 WEEK 22

1. Simple shell geometry development. 2. Geometry discretization - 2 to 3 parts 3. Robotic non-planar 3DP on formwork. 4. Fabric formwork morphologies.

DIGITAL STUDIES 1. ARCHITECTURAL GEOMETRY + DIGITAL OPTIMISATION 2. FABRIC FORMWORK STRIPS DEVELOPMENT

WEEK 23

FABRICATION SETUP STEP 02 (June 13th - June 26th)

REVIEW (June 09th) PROGRESS CHECK (June 30th)

PRODUCTION PHASE 01 STEP 03 (July 04th - July 24th)

ADDITIVE MANUFACTURE

PRODUCTION PHASE 02 STEP 03 (July 25th - Aug 14th)

CERAMIC PANEL ADDITIVE MANUFACTURING

ROBOTIC WIRECUTTING AND KILN SETUP

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

ASSEMBLY PHASE STEP 04 (Aug 20th - Oct 09th)

SHELL ASSEMBLY

MAY 18th to NOVEMBER 03rd

STEREOTOMIC ASSEMBLY OF THE CERAMIC PANELS

STEP 05 (Oct 10th - Oct 23rd)

DOCUMENTATION

STEP 06 (Oct 24th - Nov 03rd)

SUBMISSION

project delivery phase 03 draft portfolio submission final portfolio submission

BIBLIOGRAPHY

Thesis - Final Major Project

[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

BARC0060: Final Major Project STUDENT NO. 20111292

WIRECUTTING DOUBLE CURVED MINIMAL SURFACES

DISCUSSION WITH PETER

ROBOTIC MANIPULATION OF CLAY

DESIGN GEOMETRY DEVELOPMENT

ANOTHER PATHWAY - WIRECUTTING CLAY MOULDS

EXHIBITION - TOOL DEVELOPMENT & ROBOTIC MOVEMENT

ROBOTIC WIRECUTTING - SHELL GEOMETRIES

PROJECT - INITIAL TESTS Thesis - Final Major Project

MATERIAL To focus on the ‘architectural’ character of clay or similar material and to develop a suitable system as per the material behaviour.

strength

formwork

waste

COMPUTATION To tap on to the efficiency of non-conventional geometries and optimise the novel digital tools at hand.

hybrid DFMA production fresh clay leather hard fired clay

3DP - for detailing, developing variable geometry Wirecut - stereotomic finish, avoid deformation Fabric formwork - Flexibility & ease in assembly

FABRICATION To develop hybrid systems of manufacture as per the material and geometry, that provides social, economic and sustainable value.

PROJECT BACKGROUND Thesis - Final Major Project

Agile ceramic manufacture of complex geometries (thin shell variable minimal surfaces) using digitally informed robotic wirecutting and sculpting.

why?

how?

this is what the world needs!

DFM invests in ‘digital making’

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

Automation & Intelligence

Low-tech economies

‘High-volume mass customised production’ - address technological constriants for the manufacturers and the designers.

‘rich in local resources - material and labour’ - bridge the gap between craft and technology to address emergency issues.

How can efficient digital fabrication platforms aid in ceramic agility and performance to ensure sustainable material lifecycle patterns?

what?

who?

informed spatial ‘ceramic’ tectonics

DEFINING PATHWAYS Thesis - Final Major Project

PROJECT:

THESIS:

To develop a digital-physical workflow - robotic manipulation (wire cutting/sculpting) of clay to produce variable thin-shell minimal surface geometries.

To evaluate non-object oriented values from digital fabrication workflows tectonic, production and social assessment of the project.

overall agenda - thesis + project? How can fabrication

the be

collaboration of data-driven design and automated made cost-effective, accessible and sustainable?

PROJECT OUTLINE Final Major Project

thin shell structures with varying thickness + surface finishes

DIGITAL TOOL: Rationalise the geometry to simplify construction.

parameters

PHYSICAL TOOL: Efficient fabrication for complex geometries.

PRODUCTION OUTPUT: Ceramic/biomaterial components

1. Developing complex geometries (toolpath). 2. Precision of interfaces (robotic end effector). 3. Fabrication Time (against CNC) 4. Surface detailing texture (compared to 3DP) 5. Quality of surface (end tooling) 6. Stock + Workhold (Robotic behaviour) 7. Cost factor 8. Large volume production 9. Waste generation and resource consumption patterns. 10. Reusability of the negatives.

To develop complex modules of minimal surfaces using its asymptotic curves as toolpaths via a digital interface setup for robotic sculpting/wirecutting fabrication of clay.

‘intelligent fabrication systems’ - hybrid ceramic manufacturing systems simplified through robotic tooling and digital data.

‘computational design to constructional integration’ - discretising and rationalising ceramic geometries from global form.

production variability- optimising toolpath for detailed variable discrete geometries with production time in mind

‘efficient end-effector’ - the geometry in leather hard state is wirecut based on its stereotomic position to avoid distortion.

RESEARCH DESCRIPTION Final Thesis Report

01 Production assessment

Do we still need ‘Mass Production’, Mario Carpo

The Economics of ‘Digital Making’, Mario Carpo

Tectonic assessment

The use of intelligence to balance automation versus labour availability in the AEC industry, Gilles Retsin

03 Social assessment

09 The human and the Machine

10 Multi-fabrication platform

THESIS PLAN Final Major Project

june

MATERIAL

AUTOMATION, AI, AND ARCHITECTURE

end of term exhibition

The major project seeks to develop variable shell geometries through hybrid manufacturing workflows and circular design principles. Multipurpose, adaptable, and reconfigurable tools like parametric design and robotic fabrication are major driving forces. However, the key How can this novel fabrication system adapt to new materials withapproach circularwhich design principles? assessment relies on the “high volume-mass customised” production is in-turn dependent on the material behaviour and the architectural geometry.

THESIS Q.02

Test this quick production tool (wirecutter and other basic sculpting end-effectors) with a catalogue of materials

july thesis outline draft thesis

august prototype review final thesis

september

COMPUTATION

Beyond the technical assessment that focuses on the tectonics of the tools and processes, with 12 in-depth focus on robotics, the thesis 11 seeks a value assessment of these realms of ‘digital How can the taxonomy surfaceofdefine high volume-mass customised approach? making’ to of aidminimal the stakeholders the AECa industry. To provide social, economic, production and performative value by contextualising these applications in developing economies that are rich Developing efficient roboticcraft, endlocal effectors and interface for toolpaths catalogue of geometries in handmade material, anddigital cheap labour availability, like India,for the a thesis shall next, need to question and reflect on the feasibility of these physical and digital tools, through pragmatic interrogations at every step. Through the process, the aim is to question and adapt the methodologies in accordance with the context it addresses. For example, how to standardise the use of the robot or develop novel DIY high-end tools in the manufacturing process - at the-factory and at the site, alongside digital novel subtractive technique - quick production complex bio-integrated forms and analogue craftsmen in low-tech economies? Can DIY-make clay 3D printers support the How can we adapt these methodologies to low-economy to for address regional local craftsmen? How can remote robotic fabrication andcontexts collaboration designers? Can we needs? develop free-hand digitally controlled tools for unskilled labour? etc through cases.

THESIS Q.01 Production assessment

FABRICATION

THESIS Q.03

Finding intelligence in physical and digital tooling - defining the roles of the man and the machine - interaction. Lastly, the thesis shall reiterate the question from the Contextual Theory module - can ‘intelligent’ mechanization of craft add social value to technology to develop comprehensive architectural design solutions? Especially in challenging socio-economic contexts, there is a need to strike a balance between low-tech resources, craft versus high-tech fabrication solutions, technology. How can the collaboration of data-driven design and automated fabrication be made cost-effective, accessible, and sustainable? “How can artificial intelligence help make robots cheaper without limiting their abilities, in a challenging context?”

Tectonic assessment

Social assessment

FINAL PROJECT + THESIS

BIBLIOGRAPHY Thesis - Final Major Project

[1] Meibodi. M, Odaglia. P, Dillenberger. B, “MIN-MAX: REUSABLE 3D PRINTED FORMWORK FOR THIN-SHELL CONCRETE STRUCTURES”, http://papers.cumincad. org/data/works/att/caadria2021_250.pdf, n.d. [2] Meibodi. M, Odaglia. P, Dillenberger. B, “MIN-MAX: REUSABLE 3D PRINTED FORMWORK FOR THIN-SHELL CONCRETE STRUCTURES”, http://papers.cumincad. org/data/works/att/caadria2021_250.pdf, n.d. [3] Hua, H, and T Jia. “Wire cut of double-sided minimal surfaces” https://doi. org/10.1007/s00371-019-01629-2.

[7] “DigitalFUTURES: Architecture and Automation” | Mario Carpo. https://www. youtube.com/watch?v=7RfMuqa-BKk&list=PLtuu5idZ57EVFNxonqdYdttbPmAkDNA tI&index=4. [8] “DigitalFUTURES: Architecture and Automation” | Gilles Retsin. https://www. youtube.com/watch?v=7RfMuqa-BKk&list=PLtuu5idZ57EVFNxonqdYdttbPmAkDNA tI&index=4.

[4] Kalo. A, Tracy. K, Mark. T. “Robotic Sand Carving” http://papers.cumincad.org/ data/works/att/caadria2020_375.pdf, n.d.

[9] 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.

[5] Hua, H, and T Jia. “Wire cut of double-sided minimal surfaces” https://doi. org/10.1007/s00371-019-01629-2.

[10] Kalo. A, Tracy. K, Mark. T. “Robotic Sand Carving” http://papers.cumincad.org/ data/works/att/caadria2020_375.pdf, n.d.

[6] “DigitalFUTURES: Architecture and Automation” | Mario Carpo. https://www. youtube.com/watch?v=7RfMuqa-BKk&list=PLtuu5idZ57EVFNxonqdYdttbPmAkDNA tI&index=4.

[11] 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.

PROJECT GOAL

What is it? What will you produce for the FmP?

informed ‘ceramic’ tectonics

Agile ceramic manufacture of complex geometries (thin shell variable minimal surfaces) using digitally informed robotic wirecutting and sculpting.

How can efficient digital fabrication platforms aid in ceramic agility and performance to ensure sustainable material lifecycle patterns?

wire-cutting + sculpting

PHYSICAL TOOL Optimised 2-3 end effectors.

DIGITAL TOOL Workflow plugin for different toolpaths

TAXONOMY OF MODULES

METHODOLOGY

How will you achieve this?

To develop complex modules of minimal surfaces using its asymptotic curves as toolpaths via a digital interface setup for robotic sculpting/wirecutting fabrication of clay.

material Test this quick production tool (wirecutter and other basic sculpting end-effectors) with a catalogue of materials

geometry How can the taxonomy of minimal surface define a high volume-mass customised production approach?

tool Developing efficient robotic end effectors and digital interface for toolpaths for a catalogue of geometries

process

How can we adapt these methodologies to low-economy contexts to address regional needs? Finding intelligence in physical and digital tooling - defining the roles of the man and the machine - interaction.

thesis

geometry

tool

RESEARCH QUESTION

What the FmP is trying to find out?

why?

how?

this is what the world needs!

DFM invests in ‘digital making’

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

Importance of R&D in ‘High-tech manufacturing’ - Fuel economic recovery and foster innovation in the production chain.

what?

who? Low-tech economies

Automation & Intelligence

‘High-volume mass customised production’ - address technological constriants for the manufacturers and the designers.

‘rich in local resources - material and labour’ - bridge the gap between craft and technology to address emergency issues.

Agile ceramic manufacture of complex geometries (thin shell variable minimal surfaces) using digitally informed robotic wirecutting and sculpting.

PROJECT: ‘intelligent fabrication systems’ - hybrid ceramic manufacturing systems simplified through robotic tooling and digital data.

THESIS:

To develop a digital-physical workflow - robotic manipulation (wire cutting/sculpting) of clay to produce variable thin-shell minimal surface geometries.

‘computational design to constructional integration’ - discretising and rationalising ceramic geometries from global form.

production variability- optimising toolpath for detailed variable discrete geometries with production time in mind

To evaluate non-object oriented values from digital fabrication workflows tectonic, production and social assessment of the project.

How can the collaboration of data-driven design and automated fabrication be made cost-effective and accessible?

‘efficient end-effector’ - the geometry in leather hard state is wirecut based on its stereotomic position to avoid distortion.

FINDINGS - notional reflections The range of answers that you expect to see

parameters & evaluation criteria

thin shell structures with varying thickness + surface finishes 01

DIGITAL TOOL: Rationalise the geometry to simplify construction.

PHYSICAL TOOL: Efficient fabrication for complex geometries.

PRODUCTION OUTPUT: Ceramic/biomaterial components

product ‘Material Efficiency’ - Potential for high-volume production

‘Cost efficiency and Accessibility’ - Low economic context

‘Mass Customisation’ - Design and detail flexibility

‘Sustainable Value’ - Site needs and reflections

‘Digital Tool’ - Efficient user-friendly toolpath workflow

‘Physical Tool’- Simple, adaptable robotic end-effector tooling

computation

fabrication

6. Stock + Workhold (Robotic behaviour) 7. Cost factor 8. Large volume production 9. Waste generation and consumption. 10. Reusability of the negatives.

RESEARCH DESCRIPTION Final Thesis Report

01 Production assessment

Do we still need ‘Mass Production’, Mario Carpo

The Economics of ‘Digital Making’, Mario Carpo

Tectonic assessment

The use of intelligence to balance automation versus labour availability in the AEC industry, Gilles Retsin

03 Social assessment

09 The human and the Machine

10 Multi-fabrication platform

process

RESEARCH PROJECT PLAN Roadmap - Journey to final submission

june

AUTOMATION, AI, AND ARCHITECTURE

end of term exhibition

Test this quick production tool (wirecutter and other basic sculpting end-effectors) with a catalogue of materials

july thesis outline draft thesis

august prototype review final thesis

september

The thesis shall test the efficiency of the data-driven design and its impact on the customisable automated tool and vice-versa. For the physical tool, how does it change its stereotypical image of performing repetitive and precise actions to flexible, versatile, and informed interventions? Similarly, the data analytic aspect of the digital tool for performative applications seeks stronger validation. In parallel, the project seeks to optimise the technical processes of clay 3D printing, fabric formwork and wire cutting. Thus, the thesis shall intend to question the potential of an integrated manufacturing platform, given the hybrid techniques explored. Beyond the technical assessment that focuses on the tectonics of the tools and processes, with 12 in-depth focus on robotics, the thesis 11 seeks a value assessment of these realms of ‘digital How can the taxonomy surfaceofdefine high volume-mass customised approach? making’ to of aidminimal the stakeholders the AECa industry. To provide social, economic, production and performative value by contextualising these applications in developing economies that are rich Developing efficient roboticcraft, endlocal effectors and interface for toolpaths catalogue of geometries in handmade material, anddigital cheap labour availability, like India,for the a thesis shall next, need to question and reflect on the feasibility of these physical and digital tools, through pragmatic interrogations at every step. Through the process, the aim is to question and adapt the methodologies in accordance with the context it addresses. For example, how to standardise the use of the robot or develop novel DIY high-end tools in the manufacturing process - at the-factory and at the site, alongside digital novel subtractive technique - quick production complex bio-integrated forms and analogue craftsmen in low-tech economies? Can DIY-make clay 3D printers support the How can we adapt these methodologies to low-economy to for address regional local craftsmen? How can remote robotic fabrication andcontexts collaboration designers? Can we needs? develop free-hand digitally controlled tools for unskilled labour? etc through cases.

MATERIAL Tectonic assessment

COMPUTATION Production assessment

FABRICATION Social assessment

PRODUCTION