PLASTIC SELF-FORMING ADDITIVE MANUFACTURE STUDY

APPLICATION

While previous experiments have yielded promising results, the use of fabric for formwork comes with a clear drawback – the fabric's strength is insufficient for practical construction applications. Moreover, the previous workflow presents challenges in controlling the final outcome's size, also the workflow only work with isotropic shapes. In our ongoing exploration of self-forming materials, we have delved into the potential of alternative materials for self-forming processes. We've also refined the workflow and patterns to enhance control over the forming process, including the size control and the compatability with anisotropic geomatries.

Pure nylon mesh has a medium elasticity, the binding performance stands out from all materials tested, however the fabric itself is light and soft, which makes it difficult to push the printings up, leading to a subtle deformation after printing.

Referensing existing experiment on self-forming printings using fabric as the base material, the lycra and nylon are the most used materials.

After multyple material test, the nylon mixed lycra is proven to be the most suitable. It shows better elasticity, the attatchment with the printings fufill the requirement of self-forming, on top of which it's density is sufficient to push the printings to form the desired geomatry.

Material Experiment Material Deformation Study

The research workflow follows an bottom up strategie. Different from most of the similar researches, our study starts with a target geomatry input, the geomatry is then analyzed and prepared for pattern generation and simulation. Parameters such as the curvature and degree of bulkness are extracted frome the input geomatry, which is then flattened and scaled to the desired stretch degree while preserving its original topology.

The simulation is built on Kangaroo platforming following real physical lows. The result of the stretching and releasing process can be totally visualised following actural physical rule, the simulation resulting geomatry then compared with the imput to ensure an accurate result.

Curvature Analysis

BOPS (Biaxially Oriented Polystyrene) is a shape memory polymer which is produced in the form of thin flat sheet rolls, after heating the plastic will shrink and thicken into hard plastic form.

The curvature we used to generate the pattern is the principle curvatures. The reason of selecting the principle curvatures as the key parameter is that they are directional. Their value can be used to decide the density of pattern and the directions are used to determin the orientation of the patterns.

BOPS sheet with the 3d printed PLA pattern 50%

Workflow

The input geomatry is firstly flattened to mimic the starting status of the stretched fabric.

The physical simulation is built on the Kangaroo solver using constrain based solver. The basic principle is to simulate the actural physical behavior of the controled shrinking process of the fabric. According to the proposal, the gray area is the stretched fabric that followes the natrual shrinkage rate, while the white zone is the printed area that don't shrink during the releasing.

Heating and deforming process of the polymer

The final result of the polymer after heating. The thickness of the polymer increase so as the robustness.

Vertices Voronoi Area And Pattern Area Calculation

The deforming principle of BOPS is different from the fabric, the deformation is caused by the diffence of the prints coverage between the two side of the polymer. And oppsite to the fabric, higher coverage led to larger deformation.

Initial geometry is processed and analysed, which is then flattened. A pattern is generated on the flattened mesh based on analysis. This gives us the pattern which has to be 3d printed. This is further run through a Kangaroo solver that simulates the retraction process, giving us a geometry that should resemble the outcome of the physical process.

75% print coverage

The deformation is strong and led to collision between prints in some places

The area is controled through calculation of the voronoi area around each vertices to ensure the deformed geomatry share the same size with the input geomatry. The flattening method is BFF which flattens the mesh while preserving the mesh topology.

Pattern Generation

Pattern area Min curvature direction Min curvature value

The pattern that used to controld the formation is generated according to the local curvature of the input geomatry

Initial visualization of the stretched fabric with the prints on top.The simulation setup follows the actural physical property of the material. The gray area has a shrinkage rate of 1.5 while the white area that represents the prints stays rigid, which means it no shrinkage and no deformation, but certain degree of bending is allowed.

During the releasing, the fabric will shrink while the pattern preserves its initial shape and area, which will cause uneven shrinking that makes the pattern popping out from the fabric

Result

After the releasing, the accumulated deformation caused by the uneven shrinkage will change the apperence of the released fabric, which results in the self-forming performance that is controlable using different printed patterns.

Result comparision is crucial to evaluate the deviation of the self-formed the geomatry and decide whether the setup contributes to an acurate result. The parameter that is used to analyse the deviation measured using a grid of evenly destributed vertical lines, which intersects with the input and output geomatries, the distance of the intersection points on each line represents the deviation.

Ultimaker is the printing machine used in this research, filament material is PLA that is an suitainable and recyclable material that is made from corn, PLA is widly used in 3d printing craft and building area. The whole prototyping process is documented and showed in the following photos. First the nylon mixed lycra was stretched 1.5 times and covered on the printing plate, after the printing, a hardening method using plaster is tested to improve the robustness. The final model resembles largly the simutated geomatry

Simulation Result Comarision

b 1/5b

Original Voronoi area around each vertex

A = A a a b =

Area ratio between the flattened geometry and the original which is measured by each vertex Print area which doesn’t change after shrinking Empty area which will shrink into 1/5 of its original size after heating

= a = a + b = A a + 1/5b = xA a = 1.2 – 1/4xA elasitic coefficient 0.95 keep connection lines and layers perpanticular to each other

Shape fixed

Allow shrinking Allow shrinking Input Area = 1243.2 Input Gaussian curvature Output Gaussian curvature elasitic coefficient 0.45 elasitic coefficient 0.45 High Low Output Area = 1311.5 Deviation < 5%

Final length 1.5mm

THE LINK: COMMUNITY FOR THE ELDER

Harbin, almost the most north city in China, is facing crucial social problems of low subjective well-being level and population loss. Not only younger generation goes south to seek opportunities but also the major part of the north population——the elders are also heading south to spend their retired life, even if they have to leave the hometown where they have spent their entire lives at.

In this back ground, this project tempt to promote a new elder care community mode providing both thorough facilities for the elder including entertainment and basic hospitality and qualified living space specifically designed for extreme cold climate.

ACheng is a typical post industurial town in Harbin province which is an hour drive away from the city center. With an apperarent lower income level and lower city infructure de velopment comaring to the city center, the el ders here require an urgent life quality improve ment.

Apartment Layout

View Planning Analysis

The community center as well as the entrance to the community is positioned in the center of the site surving both resident and public visitors.

Architecture And Landscape Nodes

In this project, some architectural elements influenced by local culture such as the arcade language and brick texture from the immigration age. Other elements are added considering the benefit of improving elders living environment.

Activity Arcades

The public activity arcade is placed on the trim of the site with better nature view and landscape

This project is located in Achen district, Harbin, which is a major industrial city in northern China with a long history which can be traced to early 11th century.

In 1900s the Russian immigrants moved into this city and had a profound and lasting impact on both city image and economic structure.

Elevated Archways

Residence clusters are sandwiched in the middle of the community center and the public arcades to ensure an even access for every resident in the community no matter which apartment he lives in.

Elevated archways provide fast access to every conner of the community, and major indoor functions are connected by closed glass corridors allowing residents to enjoy a complete indoor route for winter activities.

The landscape on the ground level has a random form to provide an intriguing walking experience.

Second Floor Plan

Regarding to the local city image, the main material chosen for the building complex is brick and metal which gives a post-industrial taste to the residencial area. And the dark gary and crimson colored facades brings vitality to the envroment during winter when everything else looks pale.

Mr.Li, let's go to the central greenhouse to practice our Taijiquan. heard that Ms.Zhang and her friends were going to play line dancing there it'll be a great chance for you to get to know her!

Mr. Li, couldn't help but noticing you practicing Taijiquan the other day, it's so interesting that wonder maybe you would like to teach me some move if it's not too much trouble?

Let me show you some of my friends, grandson! This is Mr.Chen, my Taijiquan buddy, he taught me some new moves maybe can show you later. And that is Ms.Zhang, look how beautiful her garden is! She also gave me those tomato seeds you saw, maybe next time you come there will be some fresh home made tomate to taste!

I'm here to visit my grandpa, Mr.Li, who guess you already know considering he is a friend to your grandma. It's great to know that he is making some new friends here, he had been isolated for too long since my grandma passed away.

Project type: individual, self-inetiated project

Complete time: Dec. 2021

Rain Forest Rain Collecting Skyscraper

With the modernization of people's lives, the demand for water resources is getting higher and higher. In the past, people tended to use surface water resources and groundwater resources, but in recent years, the use of rainwater resources has gradually entered people's sight.

Shanxi is an old industrial city that has been thrived on the coal mining industry since the last century. Coal mining requires a lot of water support, and Shanxi has only the yellow river which full of sediment as the main source of surface water, which is not enough to support the factories in the province, so most of the factories use water from shanxi's groundwater. Excessive exploitation of groundwater not only caused the overall drought in Shanxi, but also caused dangerous phenomena such as ground collapse in many places.

This work attempts to use architectural means to collect rainwater resources to recharge groundwater, and through a multi-line rainwater utilization system, it saves the consumption of water resources inside the building and collects external water sources. At the same time, Considering the characteristics of high-rise buildings, the concept of water conservation is combined with the building through bionic shape, which will become a symbol of Taiyuan's green urban ecology.

Rain Water Recycling System

The Yellow River, located in northern China, is the second longest river in China. Because the middle part of the river flows through the Loess Plateau of China, it carries a lot of sediment, so it is also known as the river with the largest sediment content in the world. Therefore its water is not directly useful.

Road Network

The urban traffic network is well developed with convenient transportation, consist mainly of small and medium-sized streets.

City Density

The city fabric features a high buildings density which basically follows the form of girding.

Large urban development, high building density and hard ground around the site are unfavorable to the construction of sponge city system.

Green Area Flow Conclusion

The current site lack of usable and reachable green place which is essential to deal with extreme rain weather and reduce drainage pressure.

To mitigate the shortage of water resource in Taiyuan, some methods are applied which includes water reclamation, MAR and water source heat pump

Rainwater

The water harvested from the early state of rainfall (first flush rainwater) will be discharged because it contains more dust and pollution that are harmful to the groudwater.

The rest rainwater will be recharged into the fracture karst aquifer after simple filtration through a deep well to restore the groundwater reserves.

Water Reclaimation

Water reclamation is main emphasis of this project which is the process of converting municipal wastewater (sewage) and removed first flush rainwater into usable water for variety of purposes. By collecting and filtering the less contaminated water, the water resources can be used several times before it is released to nature.

Diagram

Site is located in the center of Taiyuan, next to a major traffic road. This highrise building is more of an iconic symble of the city to show its determination to deal with its water problem.

Through the analysis and investigation above, it is found that Taiyuan is a post industrial city with coal mine as the main industry, facing serious water problems. As the main water resource in Taiyuan, rainwater need to be used effectively to deal with the shortage of water resources.

However, due to the high development of the city, it is impossible to effectively establish the traditional sponge city system. We need to take new means to collect and utilize rainwater.

This highrise building is more of an iconic symble of the city to show its determination to deal with its water problem.

Managed Aquifer Recharge (MAR) is also applied in this project which is a purposeful recharge of water to aquifers for subsequent reuse or for environmental benefit.

It can be used to store water from various aspects such as storm-water, reclaimed water, desalinated seawater, rainwater or even groundwater from other aquifers, provided it has been previously treated. MAR can secure and enhance water supply by improving groundwater quality, preventing salt water from intruding into coastal aquifers and reducing evaporation of stored water. It can also better support ecosystems which improve local amenity, land value and biodiversity. Because the stored water is percolating through the soil towards the aquifer, the quality of the water is progressively improved thanks to natural physical, chemical and biological processes – the so-called soil-aquifer treatment.

Water Source Heat Pump

Additionally, water source heat pump also play a very important role in this project which operates much like a traditional air source heat pump except that it extracts and dissipates heat by way of water instead of air.

Traditional air source heat pumps get their heat from the air outside, but the outside temperature alters as the season change, the heat pump can be less effective. Water source heat pumps, on the other hand, work on basically the same principle, but they extract heat from a body of water which is more likely to have a constant temperature, for instance, groundwater temperature maintains between 7 °C and 12 °C all year.

A water source heat pump works using a refrigerant to transfer heat from the water to your home. The system pipes water mixed with antifreeze and heat source water through a series of coils or heat exchange panels separately. As the mixture travels through the coils, it absorbs energy from the water source and delivers this to the heat pump.

This method can also storage heat in the ground, the additional heat can be recycled by seasonally switching the extract well and the recharge well.

Mechanical Movement Diagram

Water source heat pump

Formation Diagram

The main massing features a combination of a main tower located on the north and a podium facing to street which ensure the sunlight requirement and accessibility.

The basic volume is twist to offer larger external envelop area to capture more rain and give possibility to a diverse space organization.

Vines work as both structural opponents and channel for water pipes and gutters.

The rain collectors works not only as rain collectors, but also UV blocker during summer. The water collecting system which is consist of vines and leaves can also be implant onto existing buildings without much alteration. After a vast implantation, an artificial forest will grow from human city.

Location: Hebei, China

Work type: group, professional work, shceduled to build in 2022.

Company: Beijing Institute of Architecturel design

Role: Envelop designer, 3d modeling, detail designer, construction drawing of the building envelop

Design time: Oct. 2019

Supervisor: Guo Wenhui, guowenhui@biad.com.cn

THE BRICK: UNIVERSITY TEACHING CENTER IN FLOOD DIVERSION ZONE

The project is a design of teaching building of the university campus, located in the Xiaoqinghe flood discharge area of Zhuozhou City, Hebei Province, and in order to avoid the impact on the building during the rainy season, the first floor is completely opened and all main functions are elevated to second floor. The building as a whole adopts a mixed structure of brick and concrete frame, which is coordinated with the surrounding building in terms of material, and the use of glass curtain wall is avoided in the design of the building façade to save costs. The main functions of the building are classrooms and laboratories, as well as an auditorium with the capacity of 400 people. Clear regional divisions are made in terms of functional and flow design to facilitate the learning life of students, faculty and staff.

Juma River basin where Zhuozhou campus of Labor College is located, namely Baigou river system, the North Branch of Daqing River system Jumahe river is the main source, starting from Taihang Mountain in the West.

Campus Analysis

Function Analysis

Formation Diagram

Beijuma river is divided into three branches from Beijing Fangshan District then meet at the north of Beitan village, Zhuozhou City.

From the analysis of the terrain of the whole flood diversion area, the terrain in the north of Xiaoqing River flood diversion area is very high, about 61m, and the terrain in the west is also very high, about 35 ~ 36m, while the flood discharge location in the southeast corner is very low, only 26m.

It can be seen that the flood storage and detention area is more of a flood discharge area where water mainly passes through.

Exploded View

The teaching and experiment building is located in the Southwest corner of Study zone and adjacent to the culture and sport area. As the center of both students and teachers' school life, it can play a better role here connecting the other two functions.

Road Analysis

The building is surrounded by campus road and have a direct access from the main campus entrance that connects to the city road, this makes it easier for both teacher and students to approach.

Height Analysis

Considering that the surrounding buildings are mainly short and flat we decided to keep our study center no higher than 5 storeys to achieve a better coherence with the rest of the campus.

An exhibition of the university history is displayed here. Skylight provide an aethetic light source and the wall-sized window overlookng the inner court offers an intriguing spaicial experience.

Gallary During emergency, the gallary can be used as disaster control headquater since it provides large space on a higer foor.

Canbe used as medical room or any survice room required during emengency.

Lecture room

Gradually rised seates ensure a better visual and acustic experi

Classroom

General classroom which can host 40~60 students.

Canbe used as emergency accomadation duriing flood.

SECTION A-A

Vertical flow Horizontal flow

Ground open floor

The main entrance Main functions are all elevated leaving ground floor open, this allows water to pass through during flood season keeping functional room intact.

Lifeboat can access the building from the main entrance directly on the second floor.

Student Name: Julie Wang

Student ID: 1302236

Year: 2nd

Major: Psychology

8:25 AM

Woke up late, Julie pedaled her bike really hard to catch the morning class.

14:00 PM

A ceremany is held in the university theater, people are gathering outside in the backyard so as Julie. "The cloud is getting thicker." Julie thought.

8:28 AM

Julie stormed into the building on time, she finily had a moment to catch her breath and realized what a great weather today by looking outside the glass facade while she climbing up the stairs in the court.

9:15 AM

Cozy sunlight went through the south-facing window, Julie enjoyed the lecture as well as the beautiful day.

15:50 PM

After the ceramany, Julie took a break relaxing in the north court which is a popular rest place to meet friends, chat or even proform.

17:30 AM

It was starting to rain outside while Julie was having her last class for today.

Location: China

Work type: group, professional work Company: Beijing Institute of Architecturel design

Role: Envelop designer, 3d modeling, detail designer, construction drawing of the building envelop Design time: 2019-2022

Supervisor: Guo Wenhui, guowenhui@biad.com.cn

Professional Projects Archive

This is a showcase of the projects that had contributed in during my career in BIAD. My roles were mostly the envelop designer which is in charge of the building volumn design, facade design and the modeling and technical drawings.

During my work in BIAD, had experinced the full cycle of the architectural design process from the concept design, bidding until construction tecnical design and construction consultancy survice.