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COMPONENT LINEATION|CULMINATION OF PARTS TO MAKE A WHOLE

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COMPONENT LINEATION|TABLE OF CONTENTS

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AUSTIN D. MILES

Abstract Original Exploration of Modeling First Component Assembly First Component with Forces Applied First Component Population First Component Failures Finding Rigidity Second model Exploration Second Component Assembly Forces of New Component Finding the Abstracted Geometry Population Patterning Ideas Populations in Model Fabrication Issues Grasshopper Exploration Looking for Examples

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Case study Research Case Study Research Case Study Research First global population Attempt Global Population Drawings Global Population Drawings Fabrication with Edge Connection Refabricating Global Population Fabrication Steps Modeling the Component Forces Applied to Final Component Global Population of Final Model Full Assembly in use Cost Estimations for 1-1 scale Future Exploration

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COMPONENT LINEATION|ABSTRACT

The initial aim of this project was to design a component that had structural rigidity and could then have a vast array of global population possibilities.

The original hope with those possibilities was that the global population of the component could form then, some type of canopy type system.

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Finding rigidity in the beginning was a challenge, but by the second component design, rigidity in the vertical direction had become a very strong point to work forward with. The work was then to populate out that component to from not only vertical rigidity in the component, but also horizontal rigidity, working toward that goal of forming a canopy system.

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In the end, horizontal rigidity was dropped with the intent of understanding what the component itself does best, which is populating up in the vertical direction. The global population then created an elegant column structure that was hollow and could be simply supported with thin strips in the fabrication process. In the end the initial aim was still achieved, as structural rigidity of the component was achieved, allowing the component to be structural, and not just an “architecture instillation� with no structural aspect.

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COMPONENT LINEATION|ORIGINAL EXPORATION

FIGURE 4-1

FIGURE 4-2

LARGE SURFACE EXPORATION

SINGLE GRID EXPLORATION #1

With the beginning exploration of model making, my intent was to create a component that could use both rectilinear and curvilinear folds to form a surface, as my original intent was to form some type of canopy system. This is demonstrated in Fig. 4-1.

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FIGURE 4-3

SINGLE GRID EXPLORATION #2

FIGURE 4-4

FIGURE 4-5

SINGLE GRID EXPLORATION #3 FINAL SINGLE GRID EXPLORATION

I soon realized that this was a lot to ask of one component and to make this operable, so I decided it would be best to break the component down into a grid system of a curvilinear and rectilinear fold that when populated, would form such a canopy structure. That exploration can be seen in Fig. 4-2 through Fig 4-5, to where I concluded that 4-5 fit the aim of curvilinear and rectilinear folds in a component best.

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COMPONENT LINEATION|COMPONENT ASSEMBLY

From the component that I decided to move on with (model from Fig. 4-5) I then proceeded to analyze the assembly BREAKING DOWN THE FOLDING TECHNIQUE of the model. The model is broken down into a 4x4 grid (Fig. 5-1) where the red lines indicate cut lines that divide the 4x4 grid into a FIGURE 5-1 repeating “T” pattern.

FIGURE 3-1 | Cut Paths and Fold lines

The “T” patter is then folded in a curve on the ends of horizontal element of the “T” and then pushed into a more rectilinear fold on the remaining pieces of the grid to form a shape as seen in Fig. 5-2.

FIGURE 5-2 ARCH 491

FIGURE 3-1 | Cut Paths and Fold lines

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FIGURE 3-2 | Points of folds

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FIGURE 3

COMPONENT LINEATION|ORIGINAL COMPONENT FORCES Analyzing the component then at where forces could be applied, I realized that the component handled force well at POINTS the OF RIGIDITY AND FAILURE the edges where “T” pattern was folded into a curve. The element would compress at this point, but still had some rigidity in this effort (shown in Fig. 6-1).

FIGURE 4-1

FIGURE 6-1

FIGURE 4-1

Points of folds

The point that was week though was the center where all four “T” patterns came together on just a fine edge (seen in Fig. 6-2).

This also was an issue in the beginning when looking at how the component would actually be able to hold its shape as it held POINTS OF COMPRESSION no rigid element at all.

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POINTS OF COMPRESSION POINT OF FAILURE

FIGURE 6-2

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COMPONENT LINEATION|ORIGINAL COMPONENT POPULATION Pulling off the exploration of the FIGURE 5-1 components forces, I moved on to thinking about how the FIGURE 7-1 component might actually populate, concluding that staking RESULTS FROM USING A THICKER MATERIAL (WATER COLOR PAPER) AND A LARGER SCALE TO EXPLORE CONECTIONS the component on the points of compressing would work best as demonstrated in Fig. 7-1.

LOOKING AT COMPRESSION POINTS THAT SUCCEEDED FOR ISPERATION

This might then result in to component populating in a form as URE 5-1 FIGURE 5-3 FIGURE 5-2 such in Fig. 7-2. The issue here though is that my original aim FIGURE 7-2 had focused on the component population in a way to form a plan or canopy, and this only wants to stack in ARCH 491 the vertical direction.

Also connecting the component at the BREAKING DOWN COMPONENT INTO ONE SINGLE OOKING AT COMPRESSION POINTS center is stillTHAT a large REPEATING COMPONENT UCCEEDED FOR ISPERATION issue at hand

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REPETITION OVER POINTS OF COMPRESSION WHILE JOINING AT CENTER POINT

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FIGURE 5-2

BREAKING DOW REPEATING COM

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COMPONENT LINEATION|ORIGINAL COMPONENT FAILURES FIGUREat 5-3 the With the issue of rigidity center point of thecomponent I then decided that maybe adding an element to that point of weakness might be best (Fig 8-1 and 8-2), but the issue there was that I was really just creating a second component, which simply just wouldn’t work.

FIGURE 8-1

FIGURE 8-2

OMPONENT INTO ONE SINGLE NENT

REPETITION OVER POINTS OF COMPRESSION

I then thought of the WHILE JOINING AT CENTER POINT component, looking at it as a single “T” from the grid and FIGURE 8-3 seeing how that could populate (Fig 8-3 and Fig 8-4), but that as well showed no hope of the aim of the component populating in a planer from. After this 5 it exploration I realized that was then time to go back to the drawing board and re-design the component.

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FIGURE 8-4

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COMPONENT LINEATION|ABSTRACT

FIGURE 9-1 LOOKING AT A SHEET OF PAPER AS A NON-RIGID MATERIAL FORMULATING IDEAS TO FORM RIGIDITY

Going back to the drawing board, I discovered that one of the issues with my exploration in previous models and their failures was due to the lack of rigidity. These components where composed of an element that had no rigid element due to their plainer elements of just a flat piece of paper (Fig 9-1 and Fig 9-2).

Concluding then that if I added a vertical element (Fig 9-3) in the beginning my success would then be greatly improved .

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FIGURE 9-2 PLACING THE PAPER ON EDGE FINDING RIGIDITY IN THE VERTICAL DIRECTION

FIGURE 9-3

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COMPONENT LINEATION|MODELING RIGIDITY

FIGURE 10-1

Beginning the modeling process of adding in the vertical element, I began by making surface to surface connections of a rectangular surface with a series of slits.

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FIGURE 10-3

FIGURE 10-2

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Looking at population of such a surface it the became evident that I was on a much better path than previous modeling attempts as far as how the population might fit into the original aim’s.

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Refining the element into more of a single unit, it worked much better as a single piece that was folded together using one surface to surface connection verses four.

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COMPONENT LINEATION|ASSEMBLY

Exploring the assembly of the component cutting a paper strip where each surface when folded would be three inches in length and 1.5 inches in height. The surface would then be scored and bent at an angle of 15 degree’s as marked by the red lines in Fig. 11-1. Those scores would then be folded as demonstrated in Fig 11-2, slipping together at the end of the surface with a surface to surface connection forming the closed surface and component in Fig 11-3.

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FIGURE 11-1

FIGURE 11-2

FIGURE 11-3

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COMPONENT LINEATION|FORCES APPLIED

Looking at forces that apply toAPPLIED this new component, the forces in the FORCE vertical direction work quit well in the vertical direction as seen in Fig. 12-1 where it withheld the weight of three college text books FIGURE 5-1

FIGURE 12-1 FIGURE 5-2

FIGURE 12-2

FORCE APPLIED IN THE VERTICAL DIRECTION IS ACCEPTED BEST BUT IS MUCH WEEKER AT THE HORIZONTAL AXIS

Forces in the horizontal direction (Blue arrows in Fig. 12-2) though compress the component and are not nearly as rigid as the forces that are applied in the vertical direction.

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COMPONENT LINEATION|ABSTRANCT GEOMETRY

Geometrically the component breaks down into a simple hexahedron as seen in Fig. 13-1.

FIGURE 13-1

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Looking at the abstracted geometry it becomes easy to understand how the component may populate on one corner surface of the component, where depending on the angle applied to the connection determines the amount of overlap to the connection ( Fig 13-2).

FIGURE 13-2

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COMPONENT LINEATION|POPULATING PATTERNING

Looking closer at population, stacking vertically (Fig 14-1) again best when loads are applied, but with the initial aim again of a plainer surface, this connection is not as feasible again.

FIGURE 14-1

FIGURE 14-2

Arranging the component in a chain (Fig. 14-2) works much better with the aim, but the forces are then placed on the horizontal element which ignores the quality of rigidly that the component allows for AUSTIN D. MILES

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COMPONENT LINEATION|POPULATION IN MODELING FIGURE 15-1 The abstracted geometry of the hexahedron begins to show the beauty of what the component can become as it populates at different angles of connection to form and arch that could eventually populate in a full rotation

FIGURE 15-2 Getting the arch curve from the abstracted geometry begins to become a challenge with the actual component due to connection issues as they are less free to receive such bending angles to form the arch.

FIGURE 15-3

With the frustration in populating with changing angles, I created a final example of population where the connections remained at a fixed angle that formed a rotating chain verses an arch.

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COMPONENT LINEATION|FABRICATION ISSUES

FIGURE 16-2 To resolve the issues of the arch form of population (Fig. 16-1), more mathematical evaluation will need to be applied to understand the angles that work best if forming the population of an arch as well as understanding a way to make sure that the forces are applied on the vertical axis verses the horizontal axis.

A way that might prove beneficial in adding strength to the component in the horizontal direction might best be found by fabricating the component in a contour model (Fig. 16-2) of a different material than bristol paper.

FIGURE 16-1

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COMPONENT LINEATION|EXPLORATION OF FORMING A POPULATION

FIGURE 17-1 POPULATION OF COMPONENT INTERFOLDING ONTO ONE ANOTHER

WITH THE ISSUES OF FABRICATION OF THE ORIGINAL POPULATION, THE STUDY THEN MOVED INTO USING GRASSHOPPER TO CREATE A POPULATION TO UNDERSTAND THE CONTROLE OF THE COMPONENTS CURVE. WITH THIS AN EDGE CONECTION WAS USED IN HOPES THAT IT COULD CREAT A CONECTION THAT COULD USE THE FORCES IN A MORE APLICIBLE WAY. THE IDEA WAS THEN THAT THE COMPONENT COULD THEN CURVE AS WELL AS STACK UPON ITSELF TO FORM A GLOBAL POPULATION.

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FIGURE 17-2 USING GRASSHOPPER TO CREAT A CURVING POPULATION WITH AN EDGE CONECTION

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COMPONENT LINEATION|MODELING RIGIDITY

FIGURE 18-1 Using Case studies to analize how to fabricate component

Moving on from grasshopper exploration, the focus then moved to case study research.

The hopes with case study research were to come to a realization of how fabricating such an edge connections might work with such a component as designed. Methods varied from looking at a tab connection, analyzing the angle of the curve, to contour modeling like previous hopes had led to, all of which are documented throughout the next three slides.

FIGURE 18-2 Using Case studies to analize how a population as such may be achieved

Analyzing the component then at where forces could be AUSTIN D. MILES applied, I realized that the component handled force well at the edges where the

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FIGURE 6-1

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COMPONENT LINEATION|CASE STUDIES

The central aim of the research was the development of a material system with a high degree of integration between its design and performance. This integration is inherent to natural material systems through a means of evolutionary, and mimicing it in a industrial material system.

Strips folded and bolted together, which allows for a void variety.

Materials vary from Plaster, paper and plywood

HONEYCOMB MORPHOLOGIES

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Manifold Installation Andrew Kudless/Matsys 2004

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Pericscope

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Foam Tower

Wes McGee & Brandon Clifford

COMPONENT LINEATION|CASE STUDY “Charged with the task of designing a rapidly deploy-able, temporary installation, on a limited budget, with a limited plot — we propose a tower of foam.”

50 foot tower was installed with a small team in just 6 hours Cut and created with custom robotic hotwire equipment. The lightweight EPS foam used is 90% air, and is recyclable and reusable.

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Foam Tower Wes McGee & Brandon Clifford

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Eclipse | Charles O. Perry 1973 COMPONENT LINEATION|CASE STUDY

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Aluminum Tubing that is bent into a repeating pentagon to form a spherical structure.

Large scale contour model Stands approximately 35’ tall

FIGURE 16-2

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Design Precedence

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COMPONENT LINEATION|IDEAS OF GLOBAL POPULATION

AUST

FIGURE 2 FIRST ATTEMT AT A GLOBAL POPULATION WHILE LOOKING AT FORMS TO APLYING A GRASSHOPPER DEFINITION WITH A VERTICAL FORCE. WHILE AT THE SAME TIME MAINTAINING A CANOPY TYPE STRUCTURE WITH REFRENCE TO IDEAS OBTAINED THROUGH CASE STUDY REASEARCH

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Full Component Assembly | Drawing of Assembly COMPONENT LINEATION| GLOBAL POPULATION DRAWINGS -Two Towers of 19 Stacks -76 Components Per Tower -152 Total Components 12 Feet

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9.5 Feet Tall

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Fig 4-1FIGURE | Plan View 23-1

FIRST GLOBAL POPULATION PLAN VIEW

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Fig 4-2 | Axon Perspective View

FIGURE 23-2 FIRST GLOBAL POPULATION PERSPECTIVE VIEW

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element would compress at this point, but still had some rigidity in this effort (shown in Fig. 6-1).

Full Component Assembly | Drawing of Assembly COMPONENT LINEATION| GLOBAL POPULATION DRAWINGS

POINTS OF COMPRESSION POINT OF FAILURE

FIGURE 4-1

The point that was week though was the center where all four “T” patterns came together on just a fine edgeFIGURE (seen 24-1 in Fig. 6-2).

FIRSTwas GLOBAL POPULATION This also an issue in Figbeginning 5-1 | Frontwhen Elevation View ELEVATION VIEW the looking at how the component would actually be able to hold its shape as it held no rigid element at all.

OINTS OF COMPRESSION

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BREAKING DOWN CO REPEATING COMPON

LOOKING AT COMPRESSION POINTS THAT SUCCEEDED FOR ISPERATION

FIGURE 5-1

FIGURE 4-2

FIGURE 5-3

FIGURE 5-2

FIGURE 7-2 FIGURE 6-2

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FIGURE 24-2 FIRST GLOBAL POPULATION Fig ELEVATION 5-2 | Side Elevation View VIEW

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LOOKING AT COMPRESSION POINTS THAT SUCCEEDED FOR ISPERATION

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BREAKING DOWN COMPONENT INTO ONE SINGLE REPEATING COMPONENT

FIGURE 4-2

REPETITION OVER POINTS OF COMPRESSION WHILE JOINING AT CENTER POINT

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5 FORCE APPLIED

FIGURE 11-1

Austin D. Miles | ARCH 491 | Fall 2013 AUSTIN D. MILES | FALL 2013 | ARCH_491 FIGURE 11-3

FIGURE 11-2

Exploring the assembly of the component cutting a paper strip where each surface when folded would be three inches in length and 1.5 inches in height. The surface would then be scored and bent at an angle of 15 degree’s as marked by the red lines in Fig. 11-1. Those scores would then be folded as demonstrated in Fig 11-2, slipping together at the end of the surface with a surface to surface connection forming the closed surface and component in Fig 11-3.

Looking at forces that apply toAPPLIED this new component, the forces in the FORCE vertical direction work quit well in the vertical direction as seen in Fig. 12-1 where it withheld the weight of three college text books FIGURE 5-1

FIGURE 12-1

FIG

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FIGURE 1

FORC ACCE HORI

Forces in the horizon

COMPONENT LINEATION|FABRICATION BEHIND THE EDGE CONECTION WITH FAILURES Fabricating at this point was with the contours, which still worked well with forces applied in the vertical direction, but when attempting to populate out in a canopy system as the global population demonstrated, the edge connection was still a point of weakness. There was just simply no way to formulate the edge that could vary at the angles that the grasshopper definition was asking for.

FIGURE 25.3 CONTOUR CREATING ANGLE CURVE OF PAPER MODELING

FIGURE 25.4 TOP DOWN PLAN VIEW

FIGURE 25.1 CUTTING THE ORIGINAL MODEL INTO CONTOURS

FIGURE 25.5 CREATING THE EDGE CONECTION, BUT SUPORT IS AN ISSUE AS IT FANS OUT

FIGURE 25.2 CONTOUR FABRICATION TEMPLATE

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COMPONENT LINEATION|RETHINKING THE COMPONENT

Moving forward, and with a limited time for a completed idea, the focus went to what the component itself did well all along, which was stacking vertically. It then became apparent that the system would overall work best not in a canopy system, but in simply, but elegantly, creating a column system as such in figure 26.1.

FIGURE 26.2 CREATING A COLUMN SYSTEM STACKING THE COMPONENT WITH VERTICAL RAILS

FIGURE 26.1 FOCUSING ON WHAT THE COMPONENT DOES WELL.... STACKING VERTICALLY

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COMPONENT LINEATION|FABRICATION STEPS FIGURE 27.1 TOP AND BOTOM CORDS TO SUPORT STACKING AND VERTICAL RAILS TO CREAT A SINGLE COMPONENT

Fabrication also then became the focus of a contour in the vertical direction that would complement the global population’s verticality.

FIGURE 27.2 SINGLE COMPONENT WTIH FABRICATION STEPS

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COMPONENT LINEATION|FABRICATION IN MODEL

FIGURE 28.1 FULL AGRIGATION MODEL

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FIGURE 28.2 AGRIGATION MODEL WITH FORCE APLIED (six college text books)

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FIGURE 28.3 1-1 SCALE COMPONENTS

FIGURE 28.4 1-1 SCALE COMPONENTS WITH FORCE APLIED (Aproximetly 220Ib)

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COMPONENT LINEATION|COMPONENT FORCES

FIGURE 29.1 SCAN AND SOLVE OF COMPONENT WITH NO APARNT ERRORS

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COMPONENT LINEATION|SIZE OF GLOBAL POPULATION

2 FEET

9 FEET 2 FEET

FIGURE 30.1 PLAN VIEW

1 FOOT

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FIGURE 30.2 ELEVATION VIEW

COMPONENT LINEATION|FULL ASSEMBLY USE

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FIGURE 31.1 GLOBAL POPULATION USED AS AN ACTUAL COLUMN

COMPONENT LINEATION|COST ESTIMATION

WOOD PRODUCTS *WITH USING WOOD PRODUCTS THIS HAS THE BIGGEST POSSIBILITY OF BEING ABLE TO USE SCRAP WOOD MATERIAL, WHICH WOULD BRING THE COSTS DOWN CONSIDEREABLY, AND WITH THE AID OF HAVING A MILLWORK SHOP WITH A 36” SURFACE PLANER AND SANDER, ALMOST ANY SCRAP WOOD MATERIAL COULD BE MANAGABLE. AS WELL AS FABRICATION WITH THE CNC ROUTER CAN BE EASILY APLIED.

3/4” CDX PLYWOOD ≈$25 X 3 SHEETS = $75 1/8” MASONITE ≈$25 X 3 SHEETS = $75 3/4” WOOD PAN HEAD SCREWS 1800COUNT ≈$50 LABOR = $0(IN HOUSE LABOR)

METAL PRODUCTS *WITH USING METAL AS A MATERIAL, INSTEAD OF USING A CNC ROUTER THE CUTTING WOULD HAVE TO BE DONE WITH A PLASMA CAM WHERE FABRICATION WOULD HAVE TO BE DONE OUT OF TOWN, BUT WOULD STILL BE A COST OF $0 FOR LABOR. FASTENING THE COMPONENT WOULD BE DONE WITH WELDING, AND OVERALL THE COMPONENT WOULD BE MUCH MORE STRUCTUALLY SOUND. THERE IS ALSO THE POSIBILITY OF STILL HAVING THO OPERTUNITY TO USE SCRAP MATERIAL.

1/8”- 2’X2’ STEEL SHEET ≈ $50 X 36 SHEETS = $1800 LABOR = $0(IN HOUSE LABOR)

TOTAL COST = $200 AUSTIN D. MILES

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PLASTIC PRODUCTS *WITH PLASTIC MATERIAL HAS THE BENIFIT OF BEING ABLE TO MAKE THE COMPONENT COMPLETELY TRANSPARENT WITH THE USE OF PLEXIGLASS, AND FABRICATION COSTS ARE STILL AT $0.

3/4” PVC SHEET 2’ X 2’ ≈$50 X 18 SHEETS = $900 1/8” PLEXIGLASS ≈$50 X 3 SHEETS = $150 3/4” WOOD PAN HEAD SCREWS 1800COUNT ≈$50 LABOR = $0(IN HOUSE LABOR)

TOTAL COST = $1800

TOTAL COST = $1100 32

COMPONENT LINEATION|FUTURE EXPLORATION In the end, horizontal rigidity was dropped with the intent of understanding what the component itself does best, which is populating up in the vertical direction. The global population then created an elegant column structure that was hollow and could be simply supported with thin strips in the fabrication process. In the end the initial aim was still achieved, as structural rigidity of the component was achieved, allowing the component to be structural, and not just an “architecture instillation” with no structural aspect.

FIGURE 33-1 GLOBAL POPULATION LOOKING FORWARD

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FIGURE 33-2 MODEL VARIATION EXPLORATION