The Foaming Facade - Bucky Lab by Jeroen van Veen

THE FOAMING FACADE JEROEN VAN VEEN NICK VAN DER KNAAP

BUCKY LAB 1 THE FOAMING FAÇADE

RESPONSIBLE INSTRUCTOR / Marcel Bilow TRACK / Master Building Technology COURSE / AR1AE015 Bucky Lab 2013/2014 Q3/Q4 STUDENTS / Jeroen van Veen / 4085108 Nick van der Knaap / 4099842 DATE / 23-06-2014

WHY

PRINCIPLE

FOAM

THE SYSTEM

ARCHITECTURAL APPLICATION

FINAL DESIGN

MATERIALISATION

VISUALISATION

DETAILING

THE ELEMENT

PRODUCTION

THE FINAL PROTOTYPE

STRUCTURAL MECHANICS

SUMMARY

EVALUATION

BIBLIOGRAPHY

CONCLUSION

T E C H N O L O G Y

INTRO

ELEVATOR PITCHES

ASSSIGNMENT

INTRO BUCKY LAB 4 THE FOAMING FAÇADE

INTRO

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ASSIGNMENT The assignment that is given for this exercise is not very specific, it is a wide range subject called daylight. To formulate some questions for our self, on which we can make a design, we have the specify the assignment and set some boundary conditions

calculate with the design, by doing this we will get an idea how good the design would work in real-life. With the experiments and calculations we can also decide what material the design has to be and how all the forces on the façade can be distributed.

There a lot of different factors that affect the daylight, and therefore the comfort inside the building. Things we have to think about during this exercise are: Can we use daylight more efficient, how can we protect against glare and still use the sunlight to lit up the building in a natural way? It is up to us to come up with a solution to one or more of these questions, so we can create a comfortable internal climate, in a sustainable way.

There some boundary conditions the design has to fill. The final solution will be presented in an architectural context for a multi storey office building or exhibition hall; therefore everything has to be applicable for this types. The prototype that has to be built by ourselves during the building weeks, will shows the potential, appearance and functionality of the concept, but is not the final product. This final product will be showed in renderings and 3D-models. The mock-up have some limitations due to the experiments we will do with it, so the dimensions of the mock-up are 700x1000x(max)300 mm

There are already a huge amount of products on the market that deal with daylight. So it does not mean we have to develop some new, very complicated, expensive and special system. And it also does not mean we have to use complicated materials, it is easier to use simple materials in a smart way. We have to try to develop or improve some out of the box concepts that are better but also, very important, look nicer and cooler. So we try to put some smart thoughts into a sunshade, window, façade or roof that will create better performance than the existing ones. The concept we develop has to be placed in an architectural application and we will be showed in this report with technical drawings, renderings, 3D-models, pictures of prototypes and a final mockup for the presentation. We will also experiment and

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Problem When the sun is shining too bright during the day it can be annoying. You can’t read anything on your computer screen or the sun is shining into your eyes. Most of the times when this happens people immediately close the sun shading. By doing this it gets dark, and the artificial lightning will be switched on. This is a waste of energy, so a waste of money. A better solution will be a shading that not completely blocks the sun, but makes it diffuse or blocks it locally. This will prevent people to use the artificial lightning, and reduces the energy use of the building.

INTRO

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ELEVATOR PITCHES The problem with conventional sun shading is that when the sun is too bright we close the shades. When the shades are closed the unwanted brightness of the sun is blocked. But also the daylight coming in is blocked. It becomes dark inside and the lights are turned on. This is a waste of energy and money, while free energy (sunlight) is blocked. Besides daylight is experienced by people as a far more pleasant light compared to artificial lighting. The concept involves a sun shading system which diffuses the sunlight to give a more evenly divided light intensity. It has to be a dynamic system adapting to the environment and the user of the room. Does the user like sunlight coming in? Is it not sunny but does the user want more privacy? These are questions which the system may need to adapt to. To create a light diffusing, dynamic and interactive façade system foam is used. A certain layer of foam, created by blowing air into a foaming liquid, in between two glass planes can create a pleasant and dynamic light by filtering the sunlight.

long does it take for the foam to fill the complete façade. All these aspects need to be researched thoroughly as foam is a really hard to understand substance. It is not a solid, not a liquid and not a gas.

THE FOAMING FACA THE PROBLEM

THE CONCEPT

1 it’s too light

1 diffusing lig

2 we make it too dark

2 dynamic sys

How it works In the first test two layers of glass with a 30mm cavity are filled with a small layer soap dissolved in water. By blowing air through an air diffuser, which creates very small bubbles in the liquid, the foam starts to rise in the cavity. In about one minute the complete cavity is filled with foam and is clearly diffusing the sunlight.

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FOAM

The challenges for this concept lie in controlling the foam, how to keep it clean and watertight and creating the perfect foam for the façade. If the cavity is filled with foam and air is still blown into the liquid the foam will flood the façade. There needs to be something to stop this from happening. If the façade is full of foam and the sun is gone the foam needs to be removed from the cavity. Will it disappear in time or is there a mechanical system to remove the foam? Water in a façade will obviously lead to difficulties, the right materials need to be chosen, not only to keep everything dry but also to keep everything clean as the foam tends to stick to the glass. Research need to be done to create the perfect foam for going into the cavity of the façade. Are small or large bubbles needed? Is a stable foam desirable or not? And how

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INTRO

ADE

BUCKY LAB ELEVATOR PITCH JEROEN VAN VEEN 4085108 THE TEST

THE CHALLENGES

THE POTENTIAL

Bucky Lab Semester Manual – Project summer semester 2014

tasks, dates and everything you sh bucky lab design AR1AE015 –D1 production technologies AR1AE015 –D3

ght

1 0.00min

1 controlling the foam

location of the bucky lab studio 02 West 010 This semester we will develop innovative conc exciting shapes In the first weeks of the semester every stude will be further proceeded within smaller grou Feel free to work in groups already in the beg student is able to present in the mid term pre

1. Assignment

stem

2 0.30min

2 keeping it clean

3 1.00min

3 the perfect foam

3 good ideas

AIR

INTRO

individual concept The concept of this semester have to address dutch association for lighting the NSVV – Nede (www.nsvv.nl) who will also organize the LICH lighting it up year in Den Haag. A selection of your mock up session, so a great opportunity to discuss your variety of products already on the market, we out of the box that are better, nicer, cooler or smart thoughts into a sunshade, window, faça compared to the existing ones. How can we u glare while still using the sun during the day a to be raised. Note: To create a smart concept smarter to use simple materials in a smart wa To serve you good background knowledge of will have a mini lecture day organized togethe to be named. )

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This is the elevator pitch of the design which is chosen not the continue. The concept is a facade which can block or let in sunlight from all the different directions. It has to guide or block the sunlight that you want or don’t want into your building. With the right design and use of this concept there are opportunities to save a lot of energy.

Inner Tube

Nick van der Knaa

Problem

Glare

Concept This principle is pretty simple, it’s possible to block the sunlight wherever the sun is, or let the sunlight into the room to heat it up. So in the summer we can get natural daylight, and the building will not heat up from the direct sunlight from the south. In this case we save energy due to the fact that we have to cool less because the warm direct sunlight does not enter the building, and the artificial lighting don’t has to be switched on. In the winter is the building can be heated with the direct sunlight, which can be guided into the rooms all day long. With the use of this heated sunlight the rooms have to be heated less with artificial heater, and therefore the use of energy can be reduced. So with this concept you can let heated direct sunlight enter your room whenever you need to heat up the building, or block the sun when it’s too hot inside. This can also be done with a traditional sun shading, but the big advantage is that with this principle it’s never necessary to switch on the artificial lightning when your blocking the sun. This can save a lot of energy, so money! How it works The design is made of perforated panels that are placed in front of each other. All the panels are perforated at the same height, with holes of the same width. If the panels are placed in front of each other it looks like cylinders going through the panels. These cylinders determine the amount of sunlight that enters the room, depending of the direction that they aim. It’s possible to change the direction in which the cylinders aim by shifting the panels apart from each other.

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Heating in the Summer

Cold in the Winter

Prototype

INTRO

ap | 4099842

Solution

Design Letting the sun through, untill the right tempera ture is reached.

It's getting too hot in the room or there is annoy ance of glare, the sun is blocked. When it's cold during the winter it's possible to use the sunlight to heat up the room.

INTRO

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DESIGN

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DESIGN

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WHY Why the foaming facade? Why is it better than conventional sun shading? And how is it going to be used on a building? Why the foaming facade? First of all, because it is never done before. And not for no reason. Making foam inside a facade will probably give some problems due to the fact that it has to be watertight. But this reason is not strong enough not to continue with the idea. When everything works, it will give an exciting effect that has never been seen in a facade before. It will take a lot of testing and trying but a working system is expected. A nice part about this project it that it wonâ&#x20AC;&#x2122;t be a problem if eventually the idea is not working. As long as time and effort are spend to figure everything out.

anymore the system will stop. But the foaming facade does not only work as a shading, it can also work like some kind of privacy screen. Think about a glass wall dividing offices or conference rooms. But also in the facade, at night it can be used instead of curtains. This will also give a nice view on the street because the diffuse light from the building will lit it up, and give it good atmosphere.

Why is it better than conventional sun shading? This aspect as already roughly explained in the elevator pitches. The problem with conventional sun shading is that when the sun is too bright the shades are closed. When the shades are closed the unwanted brightness of the sun is blocked. But also the daylight coming in is blocked. It becomes dark inside and the artificial lights are turned on. This is a waste of energy and money, while free energy (sunlight) is blocked. Besides daylight is experienced by people as a far more pleasant light compared to artificial lighting. The foaming sun shade is not really blocking the sun, but it diffuses the sunlight to lower the intensity. With this the sunlight is less annoying for your eyes. The nice thing about this concept is that it easily adapt to different conditions. How will the concept work in a building As said, the foam has to adapt to different needs from different people and conditions. For this, it would be nice if it can work as an interactive system which is easy to work with. People who are troubled by the intense sunlight can switch on the facade and the foam will be produced. As long as the sun is bright the system keeps working, when the sun is not shining

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Why? Just because it is fun! Who can say they designed a beer facade?!

DESIGN

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PRINCIPLE The concept of generating foam in a facade is made, but besides of designing a nice concept it also has to work for real. So there are a lot of things that have to be figured out. This paragraph will describe the things that are going to be investigated. For example how the foam could be generated, which liquid produces the best foam and how do we make sure the foam stays in the faĂ§ade for a certain amount of time? The internet is full of articles about foam, most of them highly scientific and hard to understand for people not expert in this subject. Therefore we tried to contact people with more knowledge about foam. Finally we got in contact with two people from the Heineken laboratory, who were willing to help us. With their expertise, books and the scientific articles we were able to start the research to the main principle of the concept, creating the foam. There are some basic principles to generate foam. It can be done with vibrations and carbon dioxide, vacuum or blowing in a gas. These three different principles will be discussed, and the decision of the chosen principle will be explained. Vibrations and carbon dioxide A simple way to generate foam out of a liquid is using vibrations. Maybe you are familiar with the example of tapping two beer bottles on top of each other. By tapping with a bottle on top of another one, there goes a shock-wave through the glass of the lower bottle. This vibration causes a heavy reaction that rapidly produces a foam layer on top of the beer. This principle works the same as when a soda bottle is shaken. If the bottle is opened for the first time, you hear a familiar fizz. This is the carbon dioxide gas escaping from the bottle. This gas is under pressure, because it has to keep the soda carbonated. When the cap is taken off, the pressure suddenly decreases. When the pressure on a gas decreases it expands taking up more space. This sudden expansion of that gas forces the gas out of the bottle. Most of the times the gas is collected at the top of the bottle, so when it opens it escapes with no more than a fizz. When the bottle is shaken the gas at the top is mixed with the liquid. After the shaking most of the gas

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returns to its original place at the top. However, some gas bubbles get stuck to the sides of the bottle. If the bottle is opened with these bubbles on the side, they expand rapidly and try to force their way up, through the liquid, out of the bottle. To get to the top, they must push through the soda. With this pressure they force the soda out of the bottle with a lot of foam. To get this reaction, it is a must that the foaming liquid contains enough carbon dioxide and there are enough vibrations.

Fig. 1: vibrations (top), vacuum (middle) and blowing in gas (bottom)

DESIGN

Vacuum A more complex way of creating foam is using a vacuum. With the change of pressure it’s possible to reduce and increase the amount of foam. It’s a bit the same as when the cap of a bottle with pressure is released, but with this principle there already has to be a little bit of foam present. If a small amount of foam is placed in a vacuum chamber with normal pressure it will do nothing. The atmospheric pressure keeps the foam together in a compact piece. When a vacuum is made inside the vacuum chamber the pressure decreases and the foam gets the chance to expand. Depending on its properties, the foam can grow multiple times the size of what it is under normal pressure. To let this principle work it is very important that the window in the facade is completely closed and that there are no leaks, otherwise the whole principle will fail. Making a vacuum chamber is easier being said than done. Blowing in a gas The third option is blowing in a gas. A simple example is blowing into a glass of water with a straw. By doing this big bubbles appear at the end of the straw. These bubbles rise through the glass to the surface of the water. When you do this in a liquid that can produce foam, this action will generate a layer of foam on top of the liquid. Actually the liquid will be converted into foam. The gas that you blow into the foaming liquid has to produce as tiny gas bubbles as possible, to make a foam with a high density. The higher the density, the less sunlight will go through, so the better the our concept will work. Instead of blowing the gas through a straw or tube, a sparge filter is needed as an air diffuser. The diffuser can create a lot of small gas bubbles. Also the kind of gas does affects the foam. Pure nitrogen for example is better than normal air, and helium should work the best but is very expensive. Hydrogen also is a good option but is dangerous

DESIGN

because of its fire and explosion hazard. Principle for this design For the further development of our concept we chose to use principle of blowing in gas into a foaming liquid. All the options will lead to difficulties when the concept has to be converted into a real façade element, because it is hard to make everything watertight. Especially when it has to be dismountable for maintenance. Blowing in gas, looks the least complex to us. The gas used for this application will be air, no complex gasses. We would like to keep the façade as easy as possible. The big disadvantage of the option with the use of vibrations is that the liquid always has to contain carbon dioxide. After several hours the liquid cannot for fill it needs anymore because the carbon dioxide slowly disappears out of the liquid. When the concept is implemented into a building the liquid has to be changed as little as possible, to prevent leaking and for keeping control of the costs. Also a façade that consists of a vacuum chamber does not seem that feasible. Getting the façade watertight seems difficult, but making it airtight is even harder. There is coming a big pressure on the window, this will lead to a lot of problems so we choose not to use this option. Things we have to investigate Now the principle is selected, the next problems arrive. Foam is way more complicated than it occurs on first sight. We will have to do a lot of research on the factors that will affect the quality of the foam, but also the way we can implement this system in to a façade. This is going to be explained in the two coming paragraphs. First the foam, this paragraph will show our research. What is the right liquid for the foam? How to create the right density, stability and thickness of the foam. Next the system will be described. How will the foam pumped through the façade? Is the foam pumped through the glass continuous, or does it stay in the glass and has the foam to be removed in another way?

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FOAM The most important part of the foaming facade is of course the foam itself. Foams play an important technical and industrial role and are since a long time part of everyday life. Ancient Egyptians made bread and beer where foam is a major component. Nowadays there are many applications for foams. Such as food products, personal hygiene, water purification and structural materials. Two of the main properties of foam are the bubble density and the distribution of bubble size. Where both are constantly affected by liquid drainage and bubble collapse.

Theory Foam is a multiphase mixture that consist of gas in a liquid. It can be found on a beer’s head or on top of your bath. When bubbles come together they form a foam. Fascinating structures are created by the aging, deforming, and losing liquid. Usually a foam is a mixture of many different bubble sizes, although equally distributed foams also occur. Dry- and wet foam A property of foam is the amount of liquid contained by the foam, which is referred to in the different foams, dry- or wet foams. These terms are of course relative, we can say wet foams have a liquid fraction of at least 20%, while the total liquid content in a foam ranges from 1-30%. The bubbles in dry foam are not simply spherical, but they are built up of many polyhedra which can be found in many varieties. Two rules apply to dry foam: - Faces must meet three at a time. The angles where the faces meet must be 120°, so three bubbles are joined symmetrically. - Edges must meet four. The angle between the edges is always 109.43°, so six cells meet symmetrically in every corner.

contacts is six. Although we can make a clear distinction between wet- and dry foams in theory, in real-life a lot of different liquid fractions can be found in one foam, also mixed. Liquid flows between the cells edges. The borders that are formed this way are called Plateau borders. Foam drainage Foam drainage describes the process of liquid flowing out of the foam due to gravity. The higher the foam is in a column the larger this effect is. Liquid flows down back to the reservoir ‘drying’ the foam. When the foam is collapsing, first the height of the foam remains equal. Then the foam dried further and the bubbles start to collapse resulting in a reducing height of the foam. At the end of the collapsing process a small part of the stable foam is remained on the bottom. Ripening Another effect seen in foams is ripening. The foam wants to reach a thermodynamic equilibrium. By this bubbles smaller than the average bubble size shrink while larger bubbles grow. This results in a growing of the average bubble size.

Experiments As foam is a clearly very complex substance to understand fully a lot of experimenting is done. Also there has been contact with the foam expert from Heineken to clarify the ins and outs. The properties of the foam that need to be researched are: - bubble density - uniformity of the foam - foam forming - foam drainage - amount of liquid in the foam

In wet foam the bubbles are spherical. The structure of wet foam resembles one of nature’s classic idealized coherent systems where each sphere must be in contact with at least three others. In foams with a varying bubble size the average number of these

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DESIGN

Fig. 2: dry foam (top) and wet foam (bottom)

Fig. 3: foam ripening in wet foam (left) and dry foam (right)

DESIGN

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What liquid generates the best foam? First step to research was, what is the difference between different well-known foaming liquids. There is clearly a difference in the foam formed from beer and from soap. Beer foam contains much more liquid and thus can be called a wetter foam, while the foam soap is much drier. This is also seen in the amount of liquid left in the reservoirs when the cavity is completely filled with foam. Experiments are done with various liquids and mixtures of them. Different soaps, different beers and even champagne have been tested. The soaps create larger and drier bubbles which create a very stable foam. Some staying for up to 4 hours. Beer gives a much more unstable foam, especially when the carbon dioxide is evaporated. Champagne is even more extreme when it comes to stability. In a matter of seconds the fully filled cavity is complete empty again. How can the properties of a foaming substance be changed? It could be desirable to tweak some of the properties to create the perfect foam for filling the facade. Adding different amounts of gelatine to raise the viscosity gave a very stable foam while using a relatively small amount of gelatine. What was unexpected was that the amount of gelatine did not seem to make a large difference. With the smallest amount of gelatine the before rather unstable beer foam, normally gone in under a minute, now stayed in the cavity for about three hours. By adding gelatine to water, normally not foaming at all, also lead to a stable foam. From this can be concluded that there must be something in the gelatine which stimulates the foaming apart from the increased viscosity. Also a totally stable foam can be created when the viscosity is increased further. A gel-like liquid is than created in which the bubbles will not collapse.

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Does the amount of air and pressure affect the foam? A difference in foam properties can also be observed when the amount of air, or the pressure is increased. This is tested by using an aquarium pump a bicycle pump and a compressor. The aquarium pump gives a very small volume of air under a very low pressure. This worked well with the smaller models. With larger models the pump was not able to get the foam to the top of the cavity. An easy solution for this was the bicycle pump which can be operated manually. This gives a much larger amount of air pumped through the liquid resulting in more, and a faster formed foam. A compressor has difficulties pumping at the needed low pressure and does not give a steady air flow. The generated pressure inside the cavity was not beneficial for the foam as the air pushes the foam back down. What is the best thickness of the cavity? Differences in the foam layer obviously lead to a different transparency. But also the foam density contributes to the transparency. Experiments are done with cavities varying from 3 mm to 30 mm. Where 3 mm is blocking the view, but still a lot of light shines through, while 30 mm almost does not allow any of the light through. In the final prototype a 10 mm cavity is used. Conclusion of the testing After the experiment two major foam groups can be distinguished. Foams that collapse fast and foams that collapse slow. It is now clear that the difficulty in dealing with the foam does not lie in forming the foam or getting the right density, but lies in the removing or collapsing of the foam. This is a hard to control and hard to influence. Therefore the foams that collapse fast are chosen to research further and use as a basis in the design.

DESIGN

Fig. 4: foam collapse in time

DESIGN

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THE SYSTEM The method how to produce the foam, and the right liquid are established. Now all this has to be combined in a working system, that can control the foam and which can be placed inside a façade. Making the foam The foam will be produced by blowing air into a liquid that will foam. To make the design not that complex there is decided to use air instead of a ‘special’ gas. But there are still some different options how to create pressure for the air, and how the air is diffused in the liquid. The air diffuser After having contact with the people of the Heineken laboratory, some basic information on foam is gained. To produce the foam with the smallest density, the air bubbles has to as tiny as possible. In the industry a sparge filter is used most of the times. This is a tube of pipe which is perforated so the air is diffused out of the filter. To make a filter by yourself it would take a lot of time and precision to make a good one, therefore it is easier to look for already existing ones. The local aquarium shop also has different kind of air diffuser. The first diffuser that is used was a little porous stone of 4cm long. This worked immediately pretty well, and a nice layer of foam could be generated. To create a foam into a wide glass component one of these air stones wasn’t enough, so there has to be placed multiple stones next to each other. Because the stones were not all exactly equal, one foamed better than the other. This let to different kind of foam inside the glass, something that was not desirable. Therefore a bigger air diffuser had to be found. The first attempt was a wooden one. The wood was cut perpendicular to the veins, this makes it possible to make an air flow out of the pores of the wood. We didn’t test the smaller version but in theory it should work. A bigger piece of wood was again cut perpendicular to the veins and 2 holes were drilled in

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the sides to connect the air tubes. When trying this it could be concluded that the air pressure was not strong enough. All the air came out on the sides and nothing in the middle. Even when the pressure was raised the wooden diffuser didn’t worked as hoped it would do. Even when the holes on the sides where connected into one long, narrow hole and the air could easily reach to the middle of the wood the wood didn’t diffuse the air equally, so this method was proven not to work. Again, an already existing solutions had to be used. The biggest air diffuser in the aquarium store is a 25 cm porous stone. A prototype was built around this one to see if it would work, and it did. There was a nice equal distribution of the air, which resulted in a good layer of foam with the right density no matter what the pressure of the pump was. What kind of air supply source The first tests has been done with a regular aquarium pump from the local pet shop. This pump nearly doesn’t built up any pressure, the maximum is 0.1 Bar. It worked pretty well, there was a constant flow of foam going into the glass. The only problem was the speed which the foam was produced. Because there is no pressure on the aquarium pump the flows out slowly. Therefore some test were done to find a way to produce more foam. A bicycle pump was used to raise the pressure. This immediately improved the foam production, it went faster and the foam became more dens. The only disadvantage with the bicycle pump is that it won’t pump continuous. There was no compressor available which can pump with a specific pressure, but this would be the best solution. Basis principle There are 2 main directions that can be segregated, one where there is a continuous flow of foam through a glass compartment or one where the foam stays inside the glass for a while and will be removed. The goal with this design is to keep it as simple as possible, this will make the concept more feasible, so also the system can’t be too complicated.

DESIGN

Fig. 5: air diffuser (top right) Fig. 6: first prototype using beer (bottom left) and soap (bottom right)

DESIGN

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This is the main reason why the design direction with a separate system to remove the stable foam is not continued in the research process. It is going to be though to make the glass component watertight, if extra systems are needed inside this glass. It's nearly impossible to combine all this in a watertight component. Concluded, the main direction that is going to be investigated is system where there is a continuous flow of air into the façade, which constantly generates new foam. By using foam, pressure and liquid it is difficult to design everything with drawings. So the design process would consist for a big part of making models and doing test. This will take a lot of time, but there will be less unexpected problems at the end of the design process. Prototype1; 2 air diffuser in a sealed glass compartment. The first prototype was built during the period before the elevator pitch. This prototyped already showed the feasibility of the concept. It uses two air stones, which are placed in the cavity of the glass, to form the foam. By blowing in air, with an aquarium pump, through the air stones resulted into a nice layer of foam. The thickness of the cavity is this specific model was 20mm, and the first tests showed that this thickness was more than needed. The foam inside the cavity stayed there pretty long, some different tests with both beer an soap were done. The minimal time of the foam inside the window was around 10 minutes, that’s too long for this purpose. A disadvantage with this model is that there is liquid inside the glass all the time. It is not that the liquid would affect the glass, but after a while it can leave some stains and maybe the user wants an all transparent window when the shading system is not working. So I would be better if there is a solution to get rid of the liquid in the glass cavity. Prototype 2; extra reservoir for foam generation After the elevator pitch a new prototype had to be

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made to make progress with the design. A new air stone was ordered to make a new prototype with one air diffuser for a more equal air distribution. The air diffuser is built in to an extra reservoir which will contain the foaming liquid, so it will not be visible in the window. On top of this reservoir the glass is placed, this time the cavity is reduced to 12 mm. The smaller the cavity will be, the smaller the final façade can be. This second prototypes gave a lot of extra information about how the system had to work. It showed that the reservoir under the window worked, and that one long air stone improved the quality of the foam. But still the foam stayed inside the façade for a while, a problem that had to be solved. Also the way of pumping wasn’t perfect. At the start the pump has to work hard to fill the cavity, but when it’s full it should pump slowly so foam would not escapes on the top of the window. Prototype 3; vapour permeable membrane Next, a solution against the foam flow had to be found. With the current prototype it is not possible to pump with a continuous pressure. The first solution that is tested to try to solve this problem is using a vapour permeable membrane. Normally these membranes are used inside the façade to prevent water going through so there will be no condensation. The membranes let through air, but not water. In theory, if this membrane is placed on top of the window it is possible to keep pumping. The air can escape through the membrane on top, so the pressure won’t become too high. The foam will not go through the membrane and convert back to liquid on the bottom of the membrane. The theory sounded nice, but it didn’t work at all. The amount air that was pumped into the glass was way more than the membrane could handle. The pressure rose inside the test setup. Because of this high pressure the pores of the membrane opened more than they should do. With this not only the air escaped through the membrane but also the foam. This option obviously didn’t work so there had to be another solution.

DESIGN

Fig. 7: prototype 2 with external reservoir (top & middle) Fig. 8: prototype 3 with vapour permeable membrane (bottom)

DESIGN

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Prototype 4; Extra reservoir A second solution was just let the foam escape at the top of the window. By making holes on top of the glass panel the foam easily flows out without having any trouble due to the pressure. The only problem that would have to be solved is the fact that the foam has to be collected. If you would not do that, in a few minutes all the liquid would be gone, and it is not possible to make any new foam then. Therefore it has to be some kind of circular system. This circular system is made by adding an extra reservoir on the side. A tube on top of the window is connected to the top of the reservoir. All the foam coming out of the window is transported directly into this reservoir. In here it can convert back to liquid again. Because there also is a connection between the two reservoirs at the bottom there is a closed circular system. By adding an extra reservoir the foaming liquid has to have some additional demands. If the circular system has to work, the conversion from foam to liquid has to go as fast as possible. Otherwise at a certain point the system would fail. The idea itself seems to work but the tiny tubes on the top could not handle all the pressure which accumulated inside the cavity. Therefore bigger air outlets needed to be created. With adding a hose instead of small air tube there finally was a prototype that worked the way it was planned. The biggest issue to make the perfect working system will be the kind of liquid that is used to make the foam. Implement it to other systems An important fact that has to be taken in account that this prototype is tested on a small size. It is hard to estimate how everything would work if this size is changed. The ratio between the height and width for example, or the amount of liquid needed compared to the size of the cavity. If the system would be implemented into a larger component all the test have to be done again to be sure that everything will work right. Especially the relation between the pressure and liquid is hard to understand, testing is in this case the

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easiest way to know if everything works. So for the final prototype that is produced this exact same system will be used, only it will be adjusted in size and finish. The amount of tubes on the top is increased, because the window is bigger and the diameter of the tubes is smaller. Also the reservoir is split in to two reservoirs to get an even distribution of the foam, and it is also more logical considering the frame. There was no air diffuser available as long as it was needed for the mock-up therefore the final one exists of two stones that are connected.

DESIGN

Fig. 9: Prototype 4, with external reservoir and extra reservoir for flooding foam (right & middle) Fig. 10: the final system with all the air and liquid tubes made clear (left)

DESIGN

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ARCHITECTURAL APPLICATION Now a working system is developed, it has to be placed into an architectural application. Maybe the most difficult part of the design process. Three ideas came up, all completely different. These possibilities will all be discussed, with the final choice last. Fixed system The fixed system is integrated in the design of the building. A reservoir will be placed in the floor during the build, and will not be removable. With a flap above the reservoir, it is able to reach to the system and do some adjustments. From this reservoir tubes go to the window to fill it up with foam. The side reservoirs are not drawn yet, but there will be enough space on the sides to place these. As told this idea is not elaborated any further. The biggest disadvantage was the fact that it is fixed. It cannot be placed on an already existing building, or when something is broken it is difficult to repair. It would be more ideal to have a system that can adapt easier to different situations. Plug â&#x20AC;&#x2DC;n Play The first modular system is the plug â&#x20AC;&#x2DC;n play box. A modular box which can be placed in every ordinary curtain wall that is on the market right now. The box contains a reservoir, including the air stone and everything, and a little pump. The box has two different outlets, one plug from the pump and a few tubes which can transport the foam to the window. When the box is placed in the curtain wall, only the plug has to be plugged into the power point and the system will work immediately. When the system breaks down it can be easily replaced by a new one. The biggest disadvantage is the size of the modular box. It will look a bit boring in the facade when the system is not working. There is a big box in the facade all the time, therefore it is not possible to design a nice, slim facade.

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Element Facade The final applications will be a modular element, which contains the total foaming system but also the window which will contain the foam. It will not need a curtain wall, the element can be stacked onto each other. There is a fixed connection between the elements so a sub-construction is not needed. A stack of elements will be fixed between floors, or a floor and roof. The elements will not bear the loads of these floors or roof. By using elements it is easy to install the facade on the building. Most of the work and testing will be done in the factory, this makes is fast and easy to install. The whole foaming system needs to be removable from the frame otherwise the same problem as with the first idea will occur. Therefore it has to be possible to open the element. For the further design, the profile of the element will be the most important aspect of the element. The profile has to contain the system, bear the loads and prevent the thermal bridge. When the profile is completed it can be made into a 3D element which can contain all the needed parts for the foaming system. With the design of the profile a lot of difficulties arose. The first designs where not based on a already existing element, but was totally designed from scratch. This gave a lot of problems with the strength and the thermal bridges. There is tried everything to make it work, enlarge the profile, place it in an angle, make it thicker. But nothing worked, and if it did it was way too big to become a nice slim element. After trying and trying finally was decided to take a Schuco-element as the basis for this element. This made it a lot easier to deal with all the problems, and resulted in a slim, good looking, final element. All the technical information will be shown in the next chapter.

DESIGN

Fig. 11: fixed system (top) Fig. 12: plug 'n play (bottom)

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THE FINAL DESIGN Everything is designed and developed, and ready to implement it into an element which can be placed onto a building. The system will work the same as in the final prototype but it will look pretty different. Compared with this prototype the size and scale changed. It is not sure if the system still works when the dimensions are changed, but it probably will. Chosen is a 2 by 1 meter element. With these elements stacked, multiple levels can be covered with the facade. The size of the element is not fixed. If the element is needed to span 1 floor the 2 meter element wonâ&#x20AC;&#x2122;t be big enough. It is possible to enlarge the element, when the ratio between height and width are still the same it can easily change to a 3 meter element. The element itself consists of an aluminium frame which contains two glass panels. One of structural glass to prevent the thermal bridge, and one that is connected to the foaming system. The foaming system, two reservoirs on the sides and one at the bottom, is placed between the glass panels. This complete closed element comes directly from the factory. However, the glass panel can be opened on the inside. If something is broken inside the element it can be repaired or replaced by removing the aluminium cap. By making this a double facade glass element, it can also help to make the building more energy efficient. In the winter it can work as a buffer, and in the summer the hot air can be sucked out of the panels preventing the building to heat up. The heated air can be saved in a buffer, during the winter it can used to heat up the building.

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MATERIALISATION A sub-assignment of the Bucky Lab exercise is a material science research. After doing some smaller exercises to figure out CES, a huge material database, our final Bucky Lab design had to be elaborated. We roughly divided our element in the different part, which all could be analysed. The three most interesting parts were the frame, the window which will contain the foam and the reservoirs. For all the parts some material properties had to be determined. These can be entered in a CES filter, which afterwards will show the possible materials. Some general properties were made, these belong to all the parts. And every part had some specific material properties. General properties: Resistance against UV-radiation: Good/excellent Resistance against water(fresh): Good/excellent Resistance against water(salt): Good/excellent Flammability: self-extinguishing/non-flammable Specific properties: Frame Joining method: fasteners/welding Shape: Non-Axissymmetric dished sheet Weight: Max. 100kg Window(that contains foam) Resistance against Weak alkalis: Good/excellent Resistance against Strong alkalis: Good/excellent Joining method: Adhesives Transparency: Transparent Reservoir Resistance against Weak alkalis: Good/excellent Resistance against Strong alkalis: Good/excellent Shape: Deep non-axissymmetric dished sheet Frame The most important part of the frame is that it has to bear all the loads, so has to be strong. However, because it is going to be a modular system it has to be lightweight aswell. For a stiff element we need a

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material with a high young’s modulus, but to keep it light the density has to be as small as possible. This left us with the choice of aluminium or composite. But we hadn’t involved the complex shape yet. After doing this only the aluminium was left. What kind of aluminium is needed will be chosen after the structural mechanics calculations. Window The window and reservoir have to be resistant against alkalis because they have a lot of contact with foam. Everything in the window has to be watertight, therefore it needs to be joined very tight. Fasteners easily corrode by the contact with fluids. So adhesives has to make the connection between the window panels. The final choice of material for the window depends on the weight and the stiffness. The smaller the element the smaller the stiffness can be, because there is less pressure on the window from the foam pump. In this case PVC can be used. If the size changes, and the pressure rises glass has to be used instead. Reservoirs Because it is hard to make everything watertight, it would be easier to make the reservoirs out of one piece. This leads to a deep non-axissymmetric dished sheet shape. It’s a simple shape, with low stresses and a lot of reservoirs need to be produced. It is obvious that a plastic would be the lightest and cheapest solution. Conclusion CES really did help in the designing process of the overall course. Design choices were made on results that came out of the material database. By thinking of the materialisation we even came up with the idea of one frame, that contains all the different elements. The final materials are pretty obvious, and CES is probably not needed to determine these. But by analysing every part you get new insights in your design. This really can help in the design process, and bring the design to a higher level.

DESIGN

Fig. 13: Aluminium is chosen because the wide variety of possibilities

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VISUALISATION

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DESIGN

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DESIGN

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TECHNOLOGY

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DETAILING Section 1:20 For the detailing of the final design the connection details will be shown on different scales. It starts on the next page with a 1:20 section of a facade that consists of stacked elements and elements that are connected to a floor. Both the floor and roof connection are also shown. The 1:20 details are pretty schematic, but they give an impression of how the elements are attached. For example the floor connection. In this drawing only the connection plate and the steel T-profile on the floor is showed. When this facade is really attached to a building this needs to be more detailed, for instance to prevent an eventual fire going from one floor to another. Details 1:2 The following three pages show more detailed 1:2 drawings. The details of the final element are shown in both the horizontal and the vertical direction. The core of the element is the aluminium profile, on this the reservoirs and windows are attached by clicking strips and rubbers. The tubes are also drawn, these are flexible so the actual position in the element can vary. In chapter ‘Architectural applications’ different options are shown which completely hide the foaming system and where the foam is only visible in the window. By choosing for the element, this foaming system is completely exposed. By exposing this whole system the concept reaches its full potential. But it is imaginable that not all people like the technical system, therefore also a closed element is designed. The reservoir and tubes are hidden inside the aluminium profile. A cap is placed in front of it, if something needs to be repaired or replaced this cap can be removed.

Fig. 13: elevation 1:20 (left) Fig. 14: section 1:20 (right)

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TECHNOLOGY

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Fig. 15: horizontal detail 1:2

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TECHNOLOGY

Fig. 16: vertical detail 1:2

TECHNOLOGY

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Fig. 17: horizontal detail of alternative with reservoirs behind cap 1:2

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TECHNOLOGY

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THE ELEMENT The following pages contain some 3D images which will make the element more clear. The page on the right shows an exploded view of one complete element. The next two pages show more detailed views of the corners between four connected elements. Exploded View The exploded view splits the elements in four important parts. The glass that will contain the foam and the aluminium cap which is removable to open and close the element(1). Second the aluminium frame, the core of the element(2). This will bear all the loads, and all the other parts will be attached on this frame. Next the foaming system(3). The most important part of this element. It consists of two side reservoirs, one bottom reservoir and tubes that are attached to the window. The system together with this window makes a closed circular system. Last, the glass window which protects against the outside conditions(4). Locally some extra security clips are added to the window, this to make sure the glass is not able to fall of. Corner detail The two corners show a more detailed section of the element of both the top and bottom. In the 3D-detail the bottom reservoir with the air diffuser is visible. This is where the foam is produced. The tubes on top of this reservoir go directly to the glass window to fill it up. Also the little air supply tube, that comes out of the frame and goes to the air stone, is visible. The second corner shows a detailed view of the top part of the element. The aluminium profile is the same as the one before, but it give a nice view on the tubes going from the top of the window to the side reservoirs. The clamps in the corners guide the tubes, so that they are aligned properly.

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TECHNOLOGY

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TECHNOLOGY

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PRODUCTION Fabrication The complete element will fabricated in the factory. The aluminium profiles are extruded and welded together to make a stiff core. Inside the aluminium the reservoirs and tubes are placed. These reservoirs are made out of one piece transparent plastic to minimize leaking. They are clamped in the profile by rubbers. The tubes are held to place by small aluminium attachments, which are clicked in the cavity where normally the reservoir would be. When the foaming system is placed in the aluminium frame, the element can be closed with the two glass panels. On the outside the structural glazing is glued to the frame and therefore not removable. The glass with the foam cavity is clamped to the frame with an aluminium strip, which can be clicked onto the frame. Assembly The element itself is completely prefabricated, and therefore fast and easy to install. When the elements are brought to the building site, a crane can easily lift them up and guide them to the building. The elements are attached to the floors of a building. At the end of the floors steel T-profiles are placed. These profiles contain holes, which will hold the element. The steel plates on top of the element, where also the crane is attached, fit exactly into the holes. When the first elements are placed, the next rows of elements can stacked on top of it. The connection between the elements is designed that it is fixed, so multiple elements can be stacked on each other before another attachment to the floor or roof is needed. For this reason there are two different steel assembly plates, one to connect to the floor, and one just as a connection between two elements.

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TECHNOLOGY

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THE FINAL PROTOTYPE The building weeks After weeks of testing the foaming system, and designing the element behind a computer screen there was finally time to make some fun. The building weeks give the possibility to make a final prototype of the design. By making a 3D-model on the computer a week before, and getting a good introduction on all the tools from Festool, everything was well prepared. As soon as the building was started it became clear that the prototype we designed would be way to complicated with all the sharp angles. Back to the drawing tables to make a new design. With one day lost the building week could really start. It all went pretty flawless, working with all the different machines was quickly mastered and the prototype started to get some shape. The hardest part would be making the foaming system watertight, therefore upfront there was thought of how this could be done. Chloroform was the solution. With this it is possible to ‘weld’ different layers of plexiglass to each other. This makes a watertight connection. One small problem, the whole system has to be made out of plexiglass. A fragile and difficult treatable material. Luckily it was possible to cut a lot of the part with the laser-cutter. This made all the parts of the exact dimensions which speeded up the building process. Also some nice detail like waterlevel indication could be added to the reservoirs. With the chloroform, and a little bit glue locally the whole system was watertight. The moment of truth was, would it fit in the frame? It would according to the drawing but you never know how precise both the frame and the system have come out in real-life. But everything went well. After a one and a half week of hard work the prototype was finished and ready for some tests. Still some small leaks had to be repaired but finally the prototype worked exactly as expected.

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TECHNOLOGY

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TECHNOLOGY

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STRUCTURAL MECHANICS The structural mechanics part was more useful than we thought in the beginning. It really did influence our design. Partly due to the calculations we found out we had to make some pretty big changes. Also the thermal bridge played a part in this, but it was with the first profile not possible to solve both problems. We are very pleased with the element as it is right now. The size of the element is chosen as 2 meters by 1 meter. Of course these dimensions can change, but we had to take one size to compare all the calculations of the different at the end. The calculations that we have done are maybe not that accurate because everything is simplified and not all the forces and support are integrated into the calculations. But they give an impression to how the element will react to the different forces. The most import number out of the calculations was the deformation, this was most likely the weakest part of the profile. We hoped that with placing the profiles in a angle we could solve this problem, but the deformation only increased. It was not possible to get this right because the calculation would become too complex. Thatâ&#x20AC;&#x2122;s a pity, but it helped us to make a good element. The stresses were not that important. Of course the profile has to handle the stress, but in this case the stresses were not so high that the aluminium would fail. These number only can help by choosing the right aluminium for the element. It was nice to pay some extra attention to the construction part, something that was not done before in the previous projects to this extend. It gives insights for your design and it makes the design more feasible.

Fig. 18: wind load on one element Fig. 19: wind load and deformation (top left) Fig. 20: connection distance (bottom left) Fig. 21: Diana model and deformation (right)

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TECHNOLOGY

200 mm 1 kN/m2

200 mm

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CONCLUSION

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CONCLUSION

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SUMMARY The Bucky Lab assignment this year was ‘daylight’. A wide range subject, which could be anything that had to deal with daylight. The first week everyone started separately and a lot of different concepts were developed. The two of us came up with pretty different ideas, but we were both enthusiastic about the concept of the foaming facade. It was obvious that is wouldn’t be easy to convert this to a good working final design. But we never avoid a nice challenge. The weeks after we started with a lot of testing. First of all, the basic principle of how to produce the foam. Several principles were possible, but blowing in air through a small filter was most feasible for this project. Secondly there was the foam itself. This was way more complicated than expected. Luckily we received some help from the experts of the Heineken laboratory who gave us some basis information. After a lot of testing it was able to make different kid of foams. One that last for a while, and one which vanished pretty quick. With these foams a mechanism had to be designed. Two options were still left, but at the end one had to be chosen to develop into a final design. In the first prototype the long lasting foam was used. This is immediately showed that the concept worked, but it was really difficult to remove the foam out of the closed cavity. So there was decided to make a circular system with the foam that converted back to liquid pretty fast. After making several test models for this system a good working foaming system was developed.

to be made some pretty big changes. It was nice to pay some extra attention to the construction part, something that wasn’t done before in the previous projects. It give insights in the design and it made the design more feasible. The final design is an aluminium element which contains two layer of glass. One of structural glass to prevent the thermal bridge and one that is connected to the foaming system. To show that this system really works, there is made a final prototype during the building weeks. It is mostly made out of plywood and plexiglass. Some small parts are made with help of the computer, but most of the work is done with our hands with the help of some tools. Concluding, it was an informative but mostly a real fun project. Even though there were some troubles with the water tightness and it took a lot of time, we are very pleased with the final result.

This final system had to be placed into an architectural application. Chosen is a modular element which can be pre-fabricated in the factory. Therefore it is easy to place it on the building. The material is chosen with the help of CES, a large material database. Because it is a modular element is has to be as light as possible, but still strong enough to carry the loads of the elements above. Aluminium was the most suitable for this application. Next to the material research, also a structural research had to be done. Partly due to the calculations there had

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CONCLUSION

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EVALUATION I chose the Bucky Lab course because of the experimental and practical approach. I like building things and seeing results of the work done. So Bucky Lab was an excellent choice. I liked the way all the theory and practice complement each other. Structural Mechanics, Material science and the CAD part completed this. The Material science part though, could maybe have been more interacted within the total course. The design project and process was very instructive for me. The concept of course appeared quiet simple in the beginning but lead to really a lot of problems. Also I learned much more from foam that I could ever had imagined. Foam is that complicated that I have the idea that I do not have a grip on it already, but I am very satisfied with the reached results. The cooperation with Nick was very good. I knew Nick from a previous design project. That went well so that was a reason to extend our cooperation. What is sometimes difficult for me is that, unknowingly, we are not critical enough to each other. Some things are viewed as sufficient when they maybe are not. The building weeks were nice. Building your model learns yourself a lot about what you have designed on paper and on the computer. Of course a thousand things do not work the first time. But with an excellent planning we managed to finish the mock-up, to the minute, on time.

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CONCLUSION

The Bucky Lab course is famous at the faculty of architecture. Every year several cool mock-ups are exposed in the orange hall(It’s a shame this year’s mock-ups not!). The way of integrating the building weeks into the course really attracted me to follow this course. And it fulfilled my expectations. Never before I designed such a ‘small’ object as detailed, as within this course. The architecture projects in the Bachelor were mostly about the aesthetics, and not that detailed on the technical aspect. Implementing the technical part from the start gives a way better integrated design. This way of designing asks for a new designing process, with a lot of practical work with models and testing. I liked the way of working, but it gave some unexpected difficulties. For instance, problems with using laser cutters. But it’s good to learn all these new technics and design methods and I’m glad with the final result. The foaming façade was a challenging subject, but the outcome was maybe even better that expected. We’ve developed a working system and designed it into a good looking element, I think that is an accomplishment on its own. I’ve my doubts about the feasibility of the foaming façade in real buildings. Partly due to the mechanism itself, but also the aspect of the costs. During the course costs weren’t an issue, but in our design a lot of special parts and profiles are needed. Concluding, during this course I learned a lot about subjects that haven’t been explained before during the bachelor. Subjects like mechanics, material science and computer software. And it was the first time a model is made what looks so close to the final design. Besides that I learned a lot, it also was a whole lot of fun to do!

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BIBLIOGRAPHY Bilow M. (2014) . Bucky Lab semester manual “Manual” Project summer semester 2014 – Daylight’. Delft: TU Delft Nijsse, R. (2012). Dictaat draagconstructies I. Delft: TU Delft Stevenson, P. (2012). Foam Engineering. Chichester: John Wiley & Son TU Delta. (2005). Waarom? Daarom! ‘Magazine van de technische universiteit Delft’. Delft: TU Delft

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CONCLUSION

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