MEETING NATURE HALFWAY B C K
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CONTENT EMERGENT STRUCTURES IN NATURE 05
EXPERIMENTS 47
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- Cristallization Processes - Brine Structures
MATERIAL RESEARCH 11 - Polymers - Polycaprolactone - Prefabrication Strategies
FABRICATION STRATEGIES 19 - Schemes - Manual Strategies - Robotic Strategies
Strategy Water Temperature Waterlevel Salinity Waterbasin Material Thickness Grid Size
DESIGN PROPOSAL 63 -
Details Design schemes Design proposals Visualisation
I. EMERGENT STRUCTURES IN NATURE
Emergent Structures in Nature - Crystalization
I.I. CRYSTALIZATION PROCESS
Definition Crystallization is the (natural or artificial) process of formation of solid crystals precipitating from a solution, melt or more rarely deposited directly from a gas. Crystallization is also a chemical solid–liquid separation technique, in which mass transfer of a solute from the liquid solution to a pure solid crystalline phase occurs. In chemical engineering crystallization occurs in a crystallizer. Crystallization is therefore an aspect of precipitation, obtained through a variation of the solubility conditions of the solute in the solvent, as compared to precipitation due to chemical reaction. Process The crystallization process consists of two major events, nucleation and crystal growth. Nucleation is the step where the solute molecules dispersed in the solvent start to gather into clusters, on the nanometer scale (elevating solute concentration in a small region), that become stable under the current operating conditions. These stable clusters constitute the nuclei. However, when the clusters are not stable, they dissolve. Therefore, the clusters need to reach a critical size in order to become stable nuclei. Such critical size is dictated by the operating conditions (temperature, supersaturation, etc.). It is at the stage of nucleation that the atoms arrange in a defined and periodic manner that defines the crystal structure — note that „crystal structure“ is a special term that refers to the relative arrangement of the atoms, not the macroscopic properties of the crystal (size and shape), although those are a result of the internal crystal structure. The crystal growth is the subsequent growth of the nuclei that succeed in achieving the critical cluster size. Nucleation and growth continue to occur simultaneously while the supersaturation exists. Supersaturation is the driving force of the crystallization, hence the rate of nucleation and growth is driven by the existing supersaturation in the solution. Depending upon the conditions, either nucleation or growth may be predominant over the other, and as a result, crystals with different sizes and shapes are obtained (control of crystal size and shape constitutes one of the main challenges in industrial manufacturing, such as for pharmaceuticals). Once the supersaturation is exhausted, the solid–liquid system reaches equilibrium and the crystallization is complete, unless the operating conditions are modified from equilibrium so as to supersaturate the solution again. Many compounds have the ability to crystallize with different crystal structures, a phenomenon called polymorphism. Each polymorph is in fact a different thermodynamic solid state and crystal polymorphs of the same compound exhibit different physical properties, such as dissolution rate, shape (angles between facets and facet growth rates), melting point, etc. For this reason, polymorphism is of major importance in industrial manufacture of crystalline products.
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Emergent Structures in Nature - CRYSTALIZATION
ICE STRUCTURES
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Emergent Structures in Nature - Brine Structure
I.II. SUNKEN BRINE STRUCTURES IN THE ANTARCTIC SEA
Definition Sunken brine structures, also called brinicle (brine icicle or ice stalactite) are sea ice formations below sea level. It’s formation process requires a high amount of frozen sea water and extremely cold, saline water below the existing ice structure. Structure At the time of its creation, a brinicle resembles a pipe of ice reaching down from the underside of a layer of sea ice. Inside the pipe is the super cold, super saline water being produced by the growth of the sea ice above, accumulated through brine channels. At first, a brinicle is very fragile; its walls are thin and it is largely the constant flow of colder brine that sustains its growth and hinders its melt that would be caused by the contact with the less cold surrounding water. However, as ice accumulates and becomes thicker, the brinicle becomes more stable. A brinicle can, under the proper conditions, reach down to the bottom of the sea. To do so, the flow of supercold brine from the icepack overhead must continue, the surrounding water must be significantly less saline than the brine, the water cannot be very deep, the overhead sea ice pack must be still, and currents in the area must be minimal or still. If the surrounding water is too saline, its freezing point will be too low to create a significant amount of ice around the brine plume. If the water is too deep, the brinicle is likely to break free under its own weight before reaching the ocean bed. If the icepack is mobile or currents too strong, strain will break the brinicle. Under the right conditions, including favorable ocean floor topography, a brine pool may be created. However, unlike brine pools created by cold seeps, brinicle brine pools are likely to be very transient as the brine supply will eventually cease. On reaching the seafloor, it will continue to accumulate ice as surrounding water freezes. The brine will travel along the seafloor in a down-slope direction until it reaches the lowest possible point, where it will pool. Any bottom-dwelling sea creatures, such as starfish or sea urchins can be caught in this expanding web of ice and be trapped, ultimately freezing to death. Formation The formation of ice from salt water produces marked changes in the composition of the unfrozen water. When water freezes, most impurities are forced out of solution; even ice from seawater is relatively fresh compared with the seawater it is formed from. As a result of forcing the impurities out, sea ice is very porous and spongelike, quite different from the solid ice produced when fresh water freezes. 8
Emergent Structures in Nature - Brine Structure
SINKING BRINE
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II. MATERIAL RESEARCH
Material Studies
II.I. BIOPOLYMERS - Biodegradable, phase-changing polymers
Definition Chemical compounds, consisting of linear and branched molecular chains, are known as biopolymers. They emanate from sustainable raw material or are entirely biodegradable and classified as natural- and synthetic polymers. Producing Biopolymers There are several development strategies for producing biodegradable polymers. The biomass production provides a wide range of substrates just like wood, maize, potatoes, soy, gelatin, etc. In case of using microorganisms that are obtained by extraction, the industry is able to create water-insoluble polyhydoxy-alkanoates for biomedical implants or packaging. Biotechnology and its synthesis of bio-monomers can leads towards a different kind of polymers. In example polylactides are an polymerized version of lactic acid monomers and are one of the more enhanced biopolymers because of its predictable biodegradability. A different way of enhancing monomers into polymer structures are petrochemical products with its synthesis of synthetical monomers. One of the better known petrochemical polymers is polycaprolactone. Thanks to upgrading technologies petrochemistry is nowadays only used for the first synthesis process.
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Natural Polymers These kind of polymers emanate from the synthesizing process of an polymer in the cell of a living organism. Important examples would be proteins and peptides. These enzymes, existing in every living creature, cause the vivo nutrition transport and are supporting substance, known as fibrose. Another Biopolymere, Nucleic acid, is an information carrier of genetic substance and will be found in the DNA and viri. A large number of other information and task carriers substances can be mentioned as polysaccharids and lipids. Technical Polymers According to European Bioplastics‘ definition, industrial generated biopolymers are to differentiate into three categories:
Material Studies
II.I. BIOPOLYMERS - Biodegradable, phase-changing polymers
Classification of mechanical-thermic behaviour
Biodegradable technology
Furthermore polymers are to categorize in terms of mechanicly-thermical behavior. Differentiations are elastomers, thermoset, and thermoplastic. Characteristics are glass transition temperature, melting point, reversibility of the phase change process and the service Temperature
There are several methods of decomposing biopolymers. One of the leading technique is the oxo-biodegradation where the degradation results from oxidative and cell-mediated phenomena, either simultaneously or successively. As an example the thermoplastic elastomer Polycaprolactone is decomposed by firmicutes and proteobacteria, as well as surface erosions. In most cases biopolymers are decomposed by microorganisms over a specific period of time.
Thermoplastics A thermosoftening plastic becomes moldable above a specific temperature. Upon cooling its temperature it returns to a solid state. Above its glass transition temperature and below its melting point, the physical properties of the material change drastically. The process of reheating can be repeated endlessly. Duroplasts Duroplasts can not ne further recycled. Burning the material produces highly toxic fumes. It is a resin plastic reinforced with fibers that make these materials similar to fiberglass. The process of molding is irreversible. Elastomers These polymers are fully flexible and stretchable thanks to a spaghetti-like molecular structure. The process of molding is always possible and reversible starting with a flexible initial situation.
Another method is the use of supercritical carbon oxide which under high pressure at room temperature is a solvent that can use biodegradable plastics to make polymer drug coatings. The polymer (meaning a material composed of molecules with repeating structural units that form a long chain) is used to encapsulate a drug prior to injection in the body and is based on lactic acid, a compound normally produced in the body, and is thus able to be excreted naturally. Often biomedical applications including biodegradable, elastic shape-memory polymers are used as implants in a living body. Sutures and other material aides can naturally biodegrade after a completed surgery.
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Material Phase - change Studiesmaterial
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Phase - change Materialmaterial Studies
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Material Studies
II.IV. PREMANUFACTURING STRATEGIES
Pre - manufactured components shall advance the experiments with PCL to an predictable and measurable condition. Granulate is the typical state PCL is sold, sheets and sticks are the chosen conditions for further development processes in the project. Four different manufacturing processes will be shown: three strategies for producing sheets and one strategy for sticks. To remove the material from the mold easily the most important aspect is patients. Once the material is completely cured, it simply separates itself from the mold. To speed up the cooling process it is helpful to dip the mold and material into cool water or to cool it in a freezer. To produce PCL sticks, the easiest option is to use an aluminum u - profile, heat the material and pour the PCL in to the profile. After approx. 5 to 10 minutes it is possible to remove the material out of the mold. It is important to use one pile of material or to make sure to merge the material properly, otherwise the plc-stick won’t be continuously and break easily. PCL- sheets can be produced either by placing the granulate in a mold, melt it in a stove or pour the pre - melted material into molds or compress it between two metal-, woodor plastic sheets. Especially in this case of prefabricated shapes it is essential to make sure the material is completely cured, otherwise the material will stick to the mold and the sheet won’t be planar and will have a extremely disturbed face.
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Material Studies
PCL Sheet - compressed between two plates
1.
4.
2.
PCL Sticks - molded in Aluminum U-Profiles
1.
3.
5.
6.
2.
4.
3.
5.
6.
7.
Water temperature: Room temperature: Cure time:
80 °C 20 °C 30 min
Water temperature: Room temperature: Cure time:
PCL Sheet - stove-melted granulate
1.
2.
3.
4.
Stove temperature: Room temperature: Cure time:
PCL Sheet - molded in aluminum mold
1.
4.
100 °C 20 °C 70 min
80 °C 20 °C 15 min
2.
3.
5.
Water temperature: Room temperature: Cure time:
6.
80 °C 20 °C 30 min 17
III. FABRICATION STRATEGIES
Fabrication Strategies
OVERVIEW OF PRE-ROBOTIC FABRICATION
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Fabrication Strategies
OVERVIEW OF PRE-ROBOTIC FABRICATION
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Fabrication Strategies
Fabrication Strategy
III.I.I. MELTED SUPPORTS
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Fabrication Strategies
MELTED SUPPORTS
Approach After heating up the material in hot water, thin and still deformable PCL wires will be consistently spun on a temporarily substructure. Resulting cross sections stick together and after a few minutes the structure cures. In a repetitive process of spinning the material and reheating it with a blow-dryer occurs a flowing, uniform shape. Layering of the material gives the opportunity to control the material thickness and in consequence the structural behavior. In the end the substructure will be removed. Depending on the reheating process possible shapes extend from braided to homogeneous structures.
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Fabrication Strategies
Fabrication Strategy
III.I.II. SIEVED DROPS
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Fabrication Strategies
SIEVED DROPS
Approach The PCL granulate will be heated in a hot water basin at a temperature of 60째C. The warm mass will be consistently and flat applied to a steal mesh. With the help of a blow dryer the material will be heated up further more. Concerning the heat and the air pressure the plastic runs vertically threw the grid. Comparing to the level of the cooling water underneath the grid the material cures into different shapes. At a very high water level the result appear like drops, poured into low water (bigger distance between grid and water surface) the shape is difficult to grasp but comparable to smoke formations. Affected with ice spray to conserve the vertical linear shape it is possible to cure the material fast with ice spray.
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Fabrication Strategies
Fabrication Strategy
III.I.III. RISEN SUPPORTS
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Fabrication Strategies
RISEN SUPPORTS
Approach The PCL granulate will be heated in a hot water basin at a temperature of 60째C and bundled applied to a sheet. With help of a metal rod the cooling material will be drawn in the air. Under addition of ice spray the starting point will be selective cooled down and hardened to make sure, that the material follows just the tearing direction of the stick. Ice spray makes it possible to change the direction of the structure. Existing material will be drawn to accrued nods. The resulting structure can be interpreted as a space structure.
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Fabrication Strategies
Fabrication Strategy
II.I.IV. CLAMPED STRUCTURE
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Fabrication Strategies
CLAMPED STRUCTURE
Approach Two sheets with an radial array of hooks are assembled with a distance of 40 cm. The material will be applied, either horizontally or vertically from hook to hook. It is important to apply the material fast, to make sure the wires connect with one another and stick together. Due to the lack of horizontal connections the structure is insufficient stiffened and not able to stand without any substructure.
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Fabrication Strategies
Fabrication Strategy
III.I.V. BRAIDED STRUCTURE
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Fabrication Strategies
BRAIDED STRUCTURE
Approach The warm and soft material will be applied Between two sheets in form of hand molded, thin PCL wires. Diagonal elements will be applied and with help of a diagonal rotation of the whole structure it gets additional support as cross bracing. As long as the material is still deformable it is possible to connect the wires with one another to give the structure more stiffness. As a result of the horizontal, vertical and diagonal connections the space structure is very compressive-proof and able to stand without any support or substructure.
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Fabrication Strategies
Fabrication Strategy
III.I.VI. TWISTED SHAPE
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Fabrication Strategies
TWISTED SHAPE
Approach he PCL granulate will be heated in a hot water basin at a temperature of 60째C. The warm mass will be applied to a device, attached to a cordless screwdriver. A twisted shape accures due to the down move of the material and the rotation at the same time which cooled down fast by contact to cooling water. The resulting form refers to the rotation speed.
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Fabrication Strategies
Fabrication Strategy
III.I.VII. PULLED STRUCTURE
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Fabrication Strategies
PULLED STRUCTURE
Approach The soft PCL will be placed between two sheets. With frequent moves the sheets will be pulled apart and compressed several times until the structure becomes an oben, fibrous structure. Ice spray can be helpful to contoll the pulled structure in terms of lenght and materialthickness of individual fibres.
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Fabrication Strategy
III.I.VI. CAVITY
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Fabrication Strategies
CAVITY
Approach A small whole will be drilled into a PCL - Sheet, prefabricated by compressing the material between two acryl - glass plates. Under flowing tab water and rotary motion a whole is melted into the surface. Due to the vertical flow of the hot water, the melted material will be removed. Part of the material is removed completely by the water but a thin layer is still connected to the sheet. By changing the water temperature to under 20 째C the structure will cure. This fabrication strategy makes it possible to disturb a planar surface and to create a tube.
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Fabrication Strategy
III.I.IX. FIBROUS NETWORK
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Fabrication Strategies
FIBROUS NETWORK
Approach Fibrous Network is a network of prefabricates PCL - Sticks. The sticks will be minimal heated to create a sticky surface. After heating them up they will be attached to each other. Spacers and clips avoid the structure from sticking together and falling apart. The resulting structure is a self supported network with open spaces.
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III.II. ROBOTIC FABRICATION STRATEGIES
Fabrication Strategies
Robotic Fabrication Strategy
III.II.I. Twisted, Compressed Fibers
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Fabrication Strategies
TWISTED, COMPRESSED FIBERS
Approach Goal of the compression and twisting strategies is, to merge heated and half melted PCL-Sticks to a non reversible connection and to evolve nodes. For the robotic process different tools and strategies where developed. The basic concept is it to twist the tool and conpress the sticks between two tools to create torsions. For predictability 5mm x 5mm PCL Stick where prefabricated and used in the special tools. For easy and solid extensibility the ends of the sticks can be reheated and attached in the U-Profile from the prefabrication process. The heating level is the parameter for the kind of kink in the compression process. At a low degree of plasticity the kink will be smoother than in softer condition of the material. In all the robotic fabrication strategies the PCL- Sticks where heated in a hot water basin. Water temperature and dipping time where elementary and sensitive parameters either followed by success or distortion of the torsion.
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Fabrication Strategies
ROBOTIC TOOL
Torsion Support The robot is holding the PCL-Sticks in a special holding tool, dipping the sticks in 90 째C hot water. After for 35 seconds the robot is liftin the sticks, moving to a sheet, attached to the second robot and twisting the structure 45째. After approx. 4 minutes the sticks will be cured an merged and it is possible to remove the structure out of the construction. Further methods are using special water basins, as shown on the right to define the torsion and the structure . To create an oben network of assemnled PCL-Stick it is possible to rotate the heated and soft sticks in the air with an angle of 75째. The soft sticks will follow gravity and stick together.
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Fabrication Strategies
ROBOTIC TOOL
Robot tool
Torsion Support
The PCl-Stickholder is the tool which holds the sticks in constant distances and positions. Aluminum hollow profiles are attached between two wood sheets. one sheet as lasercutet openings wit the same size of the sticks and the profiles. This Tool is attached to the Robot. Variations are possible in terms of grid and stick size, array and amount of the used sticks.
To give some variations and to move the point of torsion three types of support tools, contemplated as water basins with special bottoms, where developed: - concav bottom for twist at the very end of the structure - perforated bottom for control of the torsin and position of the end of the sticks - convex bottom with separations to create an open end of the structure and to move the point of torsion
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IV. EXPERIMENTS
Experiments
Experiment
Sunken Structure
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Experiments
SUNKEN STRUCTURE
Out of all the previous shown strategies the seived material seemed to be the most influenceable and promising strategy. By adding different parameters the material will be transformed in a random but in the same time controlled structure. Usually plastic is a molded material in conventional defined shapes. In this material and form finding research the material is supposed to follow it‘s natural behavior under accurately defined parameters and conditions. As shown in chapter III.II. on page 24/25 the material will be applied on a metal grid. For check-ability reasons the on the grid applied material is a prefabricated PCL sheet with a defined size. With help of a blow dryer and a radiation heater the material will be melted and flow threw the mesh. The waterbasin underneath the grid helps to cool down the material amd to freeze the shape. As seen in following experiments the grid size can be one parameter according to the mesh size. Other investigations are the comparison of different material thicknesses, the distant between water level and grid, the different curing behavior in different water temperatures, brine and freshwater. Due to the results of the experiments different strategies will be combined to structures which can be applied to a design proposal.
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Experiments
IV.I. WATER TEMPERATURE
Constant:
W: 20°C R: 20°C D: H:
05 cm 11 cm
T:
9 min
W: 30°C R: 20°C D: H:
05 cm 11 cm
T:
9 min
W: 40°C R: 20°C
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D: H:
05 cm 11 cm
T:
9 min
Heat temperature: 100 °C Waterbasin: 5 liter Distance water - grid: 05 cm Heating time: 9:30 min Material thickness: 04 mm Grid size: 10x10 mm
Variable:
Water temperature: 20° C 30° C 40° C
Experiments
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Experiments
IV.II. WATERLEVEL
Constant:
Waterbasin: 65 liter Water temperature: 15 °C Room temperature: 20 °C Material thickness: 05 mm Grid size: 10x10 mm
Variable:
Distance water - grid: 100 075 050 025 000
mm mm mm mm mm
Heating Method: Heating time blow dryer: 3:30 min Heating time radiant heater: 07:00 min Temperature blow dryer: 100 °C Temperature radiant heater: 150 °C
W: R: D: H:
10,00 cm 20,00 cm
T:
13:30 min
W: R:
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15 °C 20 °C
15 °C 20 °C
D: H:
10,00 cm 20,00 cm
T:
07:00 min
Experiments
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Experiments
Blow dryer W: R:
15 °C 20 °C
D: H:
07,50 cm 22,75 cm
T:
07:00 min
Radiant heater W: R:
15 °C 20 °C
D: H:
07,50 cm 22,75 cm
T:
13:30 min
Blow dryer W: R:
15 °C 20 °C
D: H:
05,00 cm 25,00 cm
T:
13:30 min
Radiant heater W: R:
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15 °C 20 °C
D: H:
05,00 cm 25,00 cm
T:
07:00 min
Experiments
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Experiments
Blow dryer W: R:
15 °C 20 °C
D: H:
02,50 cm 27,50 cm
T:
07:00 min
Radiant heater W: R:
15 °C 20 °C
D: H:
02,50 cm 27,50 cm
T:
13:30 min
Blow dryer W: R:
15 °C 20 °C
D: H:
00,00 cm 30,00 cm
T:
13:30 min
Radiant heater W: R:
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15 °C 20 °C
D: H:
00,00 cm 30,00 cm
T:
07:00 min
Experiments
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Experiments
IV.IV. SALINITY
Constant:
Fresh water W: R:
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Waterbasin: 05 liter Water temperature: 15 °C Heating time 9:30 min Heating temperature: 100 °C Heating method: Blow dryer Material thickness: 04 mm Grid size: 10x10 mm
Variable:
Brine 15 °C 20 °C
W: R:
15 °C 20 °C
D: H:
00,00 cm 30,00 cm
D: H:
00,00 cm 30,00 cm
T:
13:30 min
T:
13:30 min
Freshwater Brine
Experiments
IV.III. WATERBASIN
Constant:
Water temperature: 15 °C Heating time 9:30 min Heating temperature: 100 °C Heating method: Blow dryer Material thickness: 04 mm Grid size: 10x10 mm
Small Basin W: R:
Variable:
Waterbasin: 05 liter 65 liter
Big basin 15 °C 20 °C
W: R:
15 °C 20 °C
D: H:
00,00 cm 30,00 cm
D: H:
00,00 cm 30,00 cm
T:
13:30 min
T:
13:30 min 59
Experiments
IV.V. MATERIAL THICKNESS Constant: Constant:
02 mm
60
Waterbasin: Watertemperature: Waterbasin: Water temperature: Heating Time Heating time Heating Temperature: Heating temperature: Heating Method: Heating method: Gridsize: Grid size:
65 liter 20 째C 65 liter 20 째C min 9:30 9:30 min 100 째C 100 째C Blow Dryer Blow dryer 10x10 mm 1X1 cm
04 mm
Variable:
Material Thickness:
Variable:
Material thickness
06 mm
02mm 04mm 06mm
Experiments
IV.VI. GRID SIZE
Constant:
Waterbasin: Water temperature: Heating time Heating temperature: Heating method: Material thickness:
65 liter 20 째C 9:30 min 100 째C Blow dryer 04 mm
Variable:
Grid size
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V. DESIGN PROPOSAL
Design Proposal
DESIGN PROPOSAL: Underwater Observatory
Due to the material properties of PCL and the fabrication strategies with cold water to “freeze” the phase change state of the material, a nearby proposal is to build an underwater structure which can be build at the destination point. Realistic environments for an underwater observatory is every maritime location with a water temperature under 25°C as shown in the world map. It could be either a deep ocean diving location which gives an artificial location for ones diving experience or a restricted area in reefs and diving paradises to minimize the visitor stream to a certain areal with the benefit of an exceptional diving environment. As shown in the experiments a grid will be placed in the ocean. Floating body’s are responsible for the floating properties of the structure. The material will be poured in to the water under addition of parameters, experienced in the preliminary experiments. Possible and realistic parameters are: grid size, material thickness, and the distance between grid and water level. By comparing structures, build with hot air floating into calm water and a structure floating down a heated grid and flowing into moving water, it is reasonable to apply this strategy to a bigger scale.
Moving water 64
Calm water
Grown structure/layering
DESTINATION MAP
Water Temperatur above 25째C Continents
Water Temperature under 25 째C
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Design Proposal
DESIGN PROPOSAL: Underwater Observatory
The structure will be connected to the Platform with cable ropes. The rope is connected to single parts of the grid which will sink with the melting PCL to a certain depth of the sea. Gravity and the aluminum bar will draw a specific shape with the material, comparing to walls. Consequently the structure can gain spacial quality’s and the structure is kept from sinking and floating uncontrolled. By adding new material after melting the preliminary layer it is possible to build additive structures. With the help of the connecting ropes the layers and final depth of the structure can be controlled. As long as the floating structure is in contact with the new layer of material, the parts will connect. Post fabrication the grid will be transformed into a floating platform. After the manufacturing process is finished more Floating body’s will be integrated and the grid will be transformed into a accessible platform by covering it. To prevent the water observatory from drifting, it will be connected to weights on the sea bottom.
Flooring
Toolgrid Supportsturcture
Substructure
Floating Bodies
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Design Proposal
DESIGN PROPOSAL: Underwater Observatory Building Process
Connection Pcl Sheets Platform
Pcl Sheets Aluminum Bar
Ropes
Heat
New Material Layer
Under Water Structure
Underwater Structure Connecting Rope Aluminum Bar
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Design Proposal
SECTION
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Design Proposal
SECTION
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Design Proposal
DESIGN SCHEME
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Design Proposal
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Design Proposal
DESIGN SCHEME: Observatory
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Design Proposal
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Design Proposal
VISUALS
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Design Proposal
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