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WÊÊ PÙÊãÊ-F Ù® Ý Developing Parametric Surface Morphologies from Textile Patterning of Wood
EÙ® DçÊĦ (BSAÙ «) M ½ ®Ä IÙ® ÙÙ Ä (BSAÙ «) Y Ê TÊĦ (MLA)
Studio Report
Research Studio|Fall 2019 Wood Proto-Architecture 2.0 Integrating Design Computation and Materialization
Studio Instructor: Assistant Professor
Ehsan Baharlou, Dr. -Ing
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CONTENTS
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Aim Page 7 Chapter 01: Context
Page 9
Chapter 02: Methods
Page 15
Chapter 03: Isotropic Development
Page 19
Chapter 04: Anisotropic Development
Page 33
Chapter 05: System Development
Page 45
Chapter 06: Final Structure Design
Page 53
Chapter 07: Final Structure Fabrication
Page 61
Acknowledgements Page 75 References
Page 76
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(Source: CODA Academic)
“I think of architecture as a piece of clothing to wrap around human beings.� - Toyo Ito
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AIM Wood Proto-Fabrics aims to investigate how techniques of textile patterning can inform the shaping and fabrication of wood to create parametrically modular surfaces.
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(Source: Erwin Hauer)
CHAPTER 01 Context Defining the scope and relevance of Wood Proto-Fabrics within a lineage of related architectural projects
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Context
Inspiration Erwin Hauer’s Modular Constructivisim Based on a system of modular constructivism, Hauer created a series of sculptural screens created from modular repeated units. Each module often followed a complex curvature that interwove within itself and other modules in the screen, creating a soft diffuse light condition that would separate the interior and exterior while also controlling views between the two spaces. Though most were constructed in concrete or stone, the modular system with which Hauer followed to develop screen walls and create distinct interior/exterior conditions has served as a primary source of inspiration for the development of Wood Proto-Fabrics. FIGURE 1-1:Church in Liesing, Vienna, Austria (Source: Erwin Hauer)
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Frei Otto’s Physical Form-Finding Known for his design of lightweight structures, Frei Otto utilized a process of physical form-finding to achieve the tensile and membrane structures he created. In particular, the way in which he transformed formal lattices through tensioned connections and a strong understanding of material behavior informs the way in which the global design of this research is formulated and executed. FIGURE 1-2:German Pavilion Model (Source: frohn&rojas)
Textile Patterning A traditional practice in garment making in which folds within complete and disjoint pieces of fabric are created and joined in unique patterns to serve different purposes. Each cut pattern defines the geometry of the fabric as well as the function, ranging from patterns that create volume and curvature to patterns that reinforce a seam. Beyond the traditional patterns of darting, pleating, flouncing, and godeting, there are many more advanced practices that utilize fabric patterning to achieve much more intricate forms.
FIGURE 1-3:Garment with pleated shoulder (Source: Tomoko Nakamichi)
Context
Related Projects Intersective Laminates Through the use of slitted wood veneer components, a modular assembly was aggregated to form an unsupported curved surface. Computation was not used to determine the final geometry. Rather, a physical form-finding process was used in the aggregation of parts. This form of ‘soft control’ allowed the designers to explore the intrinsic properties of the material as they were deployed.
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FIGURE 1-4:Three of the components used (Source: Santiago, 2009)
FIGURE 1-5:Detail of aggregated components (Source: Santiago, 2009)
Sewn Timber Shell Sewn Timber Shell studies traditional garment patterning and connection techniques still used in fashion today and re-interprets them in a new material context. Fabric is replaced by thin sheets of plywood, which establishes an altered relation between material pliability and stiffness and thus introduces loadbearing capacity to the novel material system.
FIGURE 1-6:Diagram of sewing process (Source: Menges, et al., 2017)
FIGURE 1-7:View from below the surface (Source: Menges, et al., 2017)
Context
Related Projects Honeycomb Morphologies A material system inspired by the cellular geometry of the honeycomb. The double layered wall is comprised of cells with different shapes and size that are derived from folded cardboard strips. Behind the design of the form is a growth algorithm that computationally generated the honeycomb morphology as folded overlapping strips that responded to given parameters.
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FIGURE 1-8:Fabrication map of the strips (Source: Kudless, 2003)
FIGURE 1-9:Geometry of the cells along the wall (Source: Kudless, 2003)
Woven Wood Wall The researchers investigated the surface morphology of strip pattern configuration. The woven timber method develops a novel material system and fabrication process by investigating the relationship between the performance of flexible timber structures and basket weaving methods. Using thin plywood for weaving lightweight structures, the project explores the fabrication with zero framework and a temporary augmented flexibility for the assembly.
FIGURE 1-10: Fabrication map of individual strips (Source: Ezgaat Architects, 2016)
FIGURE 1-11: Assembled surface (Source: Ezgaat Architects, 2016)
Context
State-of-the-Art Tailored Structures Utilizing robotic sewing and fabricated wood shells, Tailored Structures uses wood segments derived from studies of paper folding and textile patterning to create a curved structure. In the construction process, these wood segments were bent elastically and then sewn together by a six-axis robotic arm fit with a sewing machine. A mobile cart allowed for assembly in situ.
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FIGURE 1-12:Fabric patterning studies (Source: Alvarez & Martinez, 2016)
FIGURE 1-13:Light condition below flounce (Source: Alvarez & Martinez, 2016)
Voussoir Cloud + Shell These series of installations explored an light material system based on folding wood laminates to create distinct cell types. In Voussoir Cloud, each cell has a different number of curved edges and behave slightly differently as a result. The curved edges of each “petal” produces an inflected dish form when aggregated that relies on the internal surface tension of the wood and its folds to hold its shape. The “petals” are flatter toward the base and edges where they are denser. On the interior, they have greater offset and more curvature to create the dimpled effect. As a whole, Voussoir Cloud sets out to defamiliarize structure and wood. In Voussoir Shell, a similar material system was used to achieve a suspended form instead.
FIGURE 1-15:Interior view of the structure (Source: IwamotoScott, 2008)
FIGURE 1-14:Generation of the overall geometry (Source: IwamotoScott, 2008)
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Fabric pattern templates (Source: Elizabeth Suzann)
CHAPTER 02 Methods Specifying the design and fabrication approaches that define Wood ProtoFabrics.
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Parametric Response
Light and Surface
Fabrication
Wood Proto-Fabrics
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Wood Anisotropic Behavior
Textile Patterning
FIGURE 2-1:Methods of Wood Proto-Fabrics (Source: Iribarren, Duong, Tong, 2019)
Methods
Shown in Figure 2-1 is a diagram mapping out the design approaches that define the method of Wood Proto-Fabrics. Each approach not only contributes directly to the development of the research, but also relates to other methods within the project. For instance, while textile patterning will determine the geometry we use for the individual modules, it will also influence the fabrication process. Each fabric pattern, along with its formal characteristics, is formed in a different way - whether its subtracting material or connecting two distinct pieces of material. This will in turn affect how the fabrication process is executed. Such patterns also have the potential to be parameterized in order to achieve more variability of form. These variabilities ultimately affect the surface we develop and its relationship to light. Finally, the
pattern chosen must be capable of being adapted to the material properties of wood. As a whole, the methods of Wood Proto-Fabrics is an integrated process that involves computation in the development of a parameterized form, rigorous material studies of wood, and extensive research into traditional fabric patterning techniques. The result is a surface form that is the product of design and fabrication processes integrated through computation and material understanding.
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FIGURE 2-2:Experiment integrating methods of fabrication (Source: Eric Duong)
Techniques of Textile Patterning
There is a rich history of textile patterning techniques, with many unique methods that can pushed further or combined to create new form with different aesthetic or functional qualities. Below are the methods explored in Wood Proto-Fabrics. Darting is a tapered tuck stitched in a garment in order to shape it. It consists of removing material, typically in a triangular shape to create a synclastic volume. Darts are used in all kinds of garments, everything from jeans to dresses, and can be made in a variety of shapes. Flouncing it a particular technique of ruffle making, that creates a similar look to a ruffle, but with less bulk. A wavy look is achieved by cutting a semicircular strip of fabric and straightening it such that the edges of both ends are parallel to one another.
A godet is a circle wedge that can be inserted into a flounce in order to deepen the outer floating wave without adding additional bulk at the point of attachment. Pleats are folds of fabric that are made to add volume, take in fullness, and add interest to the silhouette of a garment. They are often used as decorative features of a garment as well as in home decor. The application of these textile patterning techniques to an anisotropic material like wood requires adaptations in the fabrication method, but allows for a range of parameters that can be adjusted to modify the form. When aggregated together in the formation of a surface, each patterned module will be derived from textile patterning but takes on new form based on its interaction with wood material behavior.
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CHAPTER 03 Isotropic Development Experiment on paper to test basic fabric patterning and potential aggregation modules.
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Experiment
Fabric Patterning DARTING
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Experiment
Fabric Patterning DARTING DF1 Width
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a
4a
DF2 Length
4a a
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FF1 Radial Length
a
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b
a
2b
FF3 Radial Width
3a
5a
d d
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GF1 Radius
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a
2a
b
b
GF2 Slashline
2a
2a
2b
1/2b
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PF1
PF2
Knife Pleat
3-Sided Tube
8a
8a
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a
4a
a
2a
PF3
PF4
Box Pleat
4-Sided Tube
8a
8a
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a
2a
a
3a
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CHAPTER 04 Anisotropic Development Experiment on 1mm cross-grain maple veneer to test fabric patterning potential on future application on plywood.
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Material Experiments DARTING
DM1 Grain Orientation Synclastic
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2a
a
2a
a
2a
a
FM3 Grain Orientation Anticlastic
a
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PM3
PM2
Grain Orientation
Continuous Connection
Anticlastic
Anticlastic
6a a
6a
6a a
a
a
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PM4 Strip Lengths
PM6 End Width Variation Anticlastic
Anticlastic
6a a
PM7 Connection Orientation Anticlastic
6a 3/4a
6a a
a
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MATERIAL EXPERIMENTS Concept
KNIFE PLEATING
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BOX PLEATING
BASE MODULE 4-Sided Module
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AGGREGATIONS Experiments on Grain Orientation PC1 Grain perpendicular to long edge
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a
PC2 Grain parallel to long edge
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2/3a
FABRICATION: CONNECTIONS Bolt Connection - Edge to Edge Single Steel Bolt + Nut 1/4” Diameter 1/2” Length 20 TPI 2a
2a 4a
2a 24a
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Double Straight Steel Bolt + Nut 1/4” Diameter 1/2” Length 20 TPI 2a
2a 4a
2a 24a
Double Diagonal Steel Bolt + Nut 1/4” Diameter 1” Length 20 TPI
4a
2a a 24a
Plate Connection - Module to Module Metal Plate Steel Bolt + Nut
3/4 a
3/16” Diameter
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3/8 a
a
Plywood Plate Steel Bolt + Nut 3/16” Diameter
1/2 a
1/2 a
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CHAPTER 05 System Development Parameterize the basic module to get diverse outcomes for overall design.
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PARAMETERIZATION Unit Development Connect Points for Curves
a
a a
1/2 a
a 1/2
a
1/2 a
1/2 a
1/2
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Create Surface along the Curves
1/2 a
1/2 a
Points on Box
1/2 a
Module Iterations Basic Module
Change Width of the Edge
Change Dimension of the Box
Aggregation
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(x2)
(x9)
(x4)
(x40)
AGGREGATION Width and Length Parameterization Module Width Parameterization
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4a
3a 2a
a
Module Length Parameterization
2b
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1.5
b b
AGGREGATION Grid System Parameterization
Basic Grid System
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Grid System with Attractor Point
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CHAPTER 06 Final Structure Design Design the surface based on textile patterning experiments and digital parameterization.
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Surface Iterations
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Design Development Create Two Surfaces
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Divide Space within Surfaces into Boxes
Generate Modules in Boxes
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Final Design Adjustment
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CHAPTER 07 Final Structure Fabrication Rationalizing the experiments and global design concepts in order to build the parametric design.
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FABRICATION PLAN Row 6
Row 5
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Row 4
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Row 3
Row 2
Row 1
CONNECTION PLATES
Row 6
Row 5
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Row 4
Row 3
Row 2
Row 1
Cross Plate for Module Connection
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L-Shape Plate for Strip Connection
FABRICATION PLAN
Connected Modules
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Individual Module
Strips on Module
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DESIGN RATIONALIZATION Cut Sheets
Row 1 0 - 39
0
1
2
3
4
5
6
7
8
..
9
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Row 2 0 - 35
0
1
2
3
4
...
5
30
31
32
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Row 4
Row 5
0 - 21
0 - 19
0
1
2
3
...
18
19
20
21
34
0
1
35
2
3
..
31
32
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34
35
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39
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Row 3 0 - 23
0
1
2
3
4
...
19
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21 22
23
Row 6 0-7
...
16
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18
19
0
1
2
3
4
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Soaking the strips in hot water to improve bendability
Joining strips via cable ties
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Tying the sides of a module to limit angle
Tying modules to control the angle between them
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Assembling the strips (Source: Authors)
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Checking the modules (Source: Authors)
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ACKNOWLEDGEMENTS Special thanks to Ehsan Baharlou, Melissa Goldman and Trevor Kemp for your guidance throughout the design and fabrication development.
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References Alvarez, M., & Martinez-Parachini, E. (2016). Tailored Structures: Adaptive Robotic Fabrication Of Sewn Veneer Composites. Retrieved from Ehsan Baharlou website: https://www.ehsanbaharlou. com/?p=462 Alvarez, M., Martinez-Parachini, E., Baharlou, E., Krieg, O. D., Schwinn, T., Vasey, L., … Yuan, P. (2018, August 26). Tailored Structures, Robotic Sewing of Wooden Shells. 405–420. Retrieved from https://link. springer.com/chapter/10.1007/978-3-319-92294-2_31 Arch2O. (n.d.). Bend9 – Bending-Active Design At Pier 9. Retrieved from Arch2O website: https://www.arch2o.com/bend9-bendingactive-design-pier-9-itke/ 76
Ezgaat Architects + Noumena. (2016, April). Woven Wood. Retrieved from SBODIO32 website: https://www.sbodio32.com/wovenwood HAWK Hildesheim, & IMD TU Braunschweig. (n.d.). WovenWoodWall by TU Braunschweig. Retrieved September 3, 2019, from Pollmeier website: https://www.pollmeier.com/en/references/sixties-style-wallcladding.html#gref IwamotoScott Architecture. (2008). Voussoir Cloud. Retrieved from IwamotoScott Architecture website: https://iwamotoscott.com/ projects/voussoir-cloud Kudless, A. (2003, 2004). Honeycomb Morphologies. Retrieved September 3, 2019, from http://www.achimmenges.net/?p=4405 Menges, A., & Knippers, J. (n.d.). ICD/ITKE Research Pavilion 2010. Retrieved September 28, 2019, from Institute for Computational Design and Construction website: https://icd.uni-stuttgart. de/?p=4458 Menges, A., Yuan, P., Hua, C., Leder, S., Soana, V., & Jimenez, I. (2017). ICD Sewn Timber Shell 2017. Retrieved September 3, 2019, from http://www.achimmenges.net/?p=20794 Santiago, E. (2009). Intersective Laminates. Retrieved September 3, 2019, from http://www.achimmenges.net/?p=4354
Abstract: Wood Proto-Fabrics is an invesƟgaƟon of how techniques of texƟle paƩerning and the material properƟes of wood can be used to develop a fabric-like surface through a prototypical design process. The module that spans the surface is derived from a series of experiments that tested how paƩerns such as darƟng, flouncing, and pleaƟng would interact with the bending behavior of wood. Through these experimentaƟons, the pleat was decided upon as the foundaƟon for the module because of its volumetric properƟes and potenƟal for parameterizaƟon. Within the final design, the module is formed from a four-sided pleat connecƟon of birch plywood strips. This module is then twisted and connected to others via a plate connecƟon at its end points. When aggregated, the result is a flexible surface of both solid and void, capable of assuming forms that define space and wrap its occupants. Digital parameterizaƟon served as the basis for the modular aggregaƟon of the final design. The form was generated between two curved surfaces and a density value of modules within a resulƟng grid. Then, aƩractor points were applied to the grid to modulate the dimensions of the individual strips within each module. This results in a visible gradient within the form, beginning with shorter and wider modules at the base and ending in longer and thinner modules. From the digital model, the modules were translated to a series of construcƟble plywood strips that are assembled according to a physical form-finding process.