digital manufacturing processes | ARCH 8790 jason boyd | fall 2016
digital manufacturing processes | ARCH 8790 The projects completed during the DMP seminar focused my exploration into contemporary digital processes and how they are transforming traditional building materials. By taking a “hands-on” lab utilizing Clemson’s SOA Digital Design Shop and Materials Lab, I was able to thoughtfully work through concepts, explore fabrication methods and tooling capabilities relevant to the manufacturing process.
digital manufacturing processes | ARCH 8790 PROJECT 1: re-patterning PROJECT 2: gradient PROJECT 3: re-thinking the brick
re-patterning: Poppin’ Pills Use the tooling possible on the CNC router in a process that alters and transforms a single sheet of mdf to arrive at a new material state for a wall panel. Poppin’ Pills is a project that is an exploration into the digital manufacturing process. In this case, a machine (CNC router) was used to “erode” the material (0.75” mdf) by using a milling bit (0.25” ball mill). An investigation into materiality and material translucency fueled the design of my panel. Two determining parameters were tested: 1) material erosion: the threshold of the material at which it becomes translucent while maintaining the structural integrity of the material 2) light intensity: the relationship between the density of the tooling path and intensity at which light penetrates the material Excavating the mdf to a thickness of 1/64” was the estimated threshold at which light would be visible through the material. By varying the density of the horizontal scalloping (the tooling profile characteristic of a ball mill) a gradient of translucency is created. The horizontal centerline becomes the brightest strip which is the area with the densest amount of lines. A gradient of reduced horizontal line density expands toward the top and bottom of the panel. These purposefully tooled variations create a visible display of light gradient penetrating the mdf. By choreographing various depths and sizes of extruded “pills,” shadows are cast in a unique gradient as well. The placement of these extrusions at different points throughout the panel alter the appearance of each pill. The overall goal was to take a 2D linear path into the 3D realm of light and shadows while pushing the material to its breaking point.
wall panel system
eroding material
tooling exploration
cnc fabricated wall panel
gradient of translucency
gradient: Melting Light Engage the 3D printer as a fabrication device to successfully differentiate light with translucent wood PLA material in the form of an enclosure for a light bulb. The premise behind Melting Light was to create a dialogue between the material of the enclosure and light energy. The resulting form is one that represents the destabilization of the material under high heat. At this moment in time, gravity becomes the molder and shaper of the enclosure. At rest, the melting form appears solid and impenetrable to light, but when activated, the enclosure reveals its translucent behavior. At the same time, the diagrid infill, a structural element implicit with 3D printing, helps maintain the integrity of the light enclosure as it is ingrained in its form. The differentiation of light that occurs in the patterning and the object’s translucency captures the dialogue between materiality and it physical representation.
digital process
3d printed light enclosure
differentiation of light
re-thinking the brick: DIGI_BRICK
ARCH 8790
Use the ceramic 3D printer to re-invent the brick and to explore unprecedented and new opportunities for integration and aesthetics. Brick is an ancient material and could be considered the first instance of “additive manufacturing.� However, we are now in an age of advanced computational methods which enables architects to re-think the brick through 3D printing. My exploration began with a simple idea: what can the surface of a brick represent? My goal was to utilize the digital manufacturing process to re-think the brick facade by deploying imagery to its surface, essentially altering the traditional brick wall into a three dimensional canvas. I envisioned each brick becoming pixels of a larger image that has the ability to represent art, culture and ideas. These brick canvases would encourage people to stop and experience not just the imagery but the materiality of the brick, and would deliver the digital manufacturing process to the public. One of the main design goals for my brick was to eliminate the exposed mortar joint that is inherent with typical brick walls. By shifting the surface of the brick, and its overall shape, an offset was created to allow for a seamless appearance, effectively hiding the mortar joints within the brick wall assembly. As a result, the DIGI_BRICK system becomes one continuous canvas for any digital image to be displayed. Relevant application in architecture: creative solution for re-envisioning abandoned big box architecture. The derelict Walmarts that populate our urban landscape have become an increasing problem and an eyesore for communities. DIGI_BRICK wall systems provide an opportunity to reconcile this architectural issue by transforming these abandoned sites into vibrant spaces for the public.
iterative process
_PREMISE_____________________________APPLICATION_____________ DIGI_BRICK is a cheap, practical and extremely creative solution for re-envisioning abandoned big box architecture. The derelict Walmarts that populate our urban landscape have become an increasing problem and an eyesore for communities. DIGI_BRICK wall systems provide an opportunity to reconcile this architectural issue by transforming these abandoned sites into vibrant spaces for the public.
Imagine being able to use a brick wall as a blank canvas that can express anything you want: art, ideas, culture. The DIGI_BRICK does just that! Through 3D printing technology, we can start to re-think how the traditional flat brick can be developed into a three dimensional surface. DIGI_BRICK delivers the digital manufacturing process to the public by deploying imagery to the face of the brick as an articulated surface.
Promote ART, CULTURE, IDEAS
BRICK WALL
3D SURFACE
Abandoned Walmart
____________________PROCESS_ DIGITAL IMAGE
Digital Image
IMAGERY + BRICK
DIGI_BRICK WALL ASSEMBLY
_DIGI_BRICK__________________________________________________ Deployed DIGI_BRICK Assembly
brochure: final brick design
_SPECS______________________________________ One of the main design goals for the DIGI_BRICK is to eliminate the mortar joint that is inherent with typical brick walls. By shifting the surface of the brick, and the overall shape of the brick, an offset is created to allow for a seamless
appearance. This process effectively hides the mortar joints inside the brick wall assembly. As a result, the DIGI_BRICK system becomes one continuous canvas for any digital image to be displayed and ejoyed.
DIGI_BRICK
WHERE DIGITAL IMAGERY AND THE BUILT ENVIRONMENT CONVERGE
ELEVATION
SHIFTING BRICK GEOMETRY
[
Overall Dimensions: 4.5" D x 5" H x 6" L
]
HORIZONTAL SECTION
VERTICAL SECTION
[
1. HIDDEN MORTAR JOINTS 2. BRICK SEAM OVERLAPS
]
___________________________________________
JASON BOYD | ARCH 8790
ceramic 3d printed brick assembly
digital manufacturing processes | ARCH 8790 | jason boyd