BartlettAD-RC4-WireVoxels

WIREVOXELS // INTERLACE

Research Cluster 4, 2015-2016 M.Arch Architectural Design

UCL, The Bartlett School of Architecture

RESEARCH CLUSTER 4, GILLES RETSIN, MANUEL JIMENEZ WIREVOXELS: MEIZI LI, ONYEE WONG, DONGHWI KIM, SUPAKIJ HOMTHONG

CONTENTS 00 INTRODUCTION

07

00.01 RESEARCH STRAND

08

00.02 MATERIALITY

10

00.03 PRECEDENT STUDIES

12

00.03 DIGITAL DESIGN AND FABRICATION

14

01 INITIAL DESIGN

19

01.01 INITIAL DESIGN : VOXEL

20

01.02 INITIAL DESIGN : TILE

22

01.03 CHAIR VOXELISATION AND TOPOLOGY STUDY

24

02 INITIAL FABRICATION

27

02.01 MATERIAL TEST

28

02.02 CASTING AND ASSEMBLY

30

02.03 FABRICATED CHAIR

32

03 DESIGN DEVELOPMENT 1

35

03.01 INITIAL CURVES DEVELOPMENT

36

03.02 TEST CASE : CHAIR

38

04 DESIGN DEVELOPMENT 2

41

04.01 METAL WIRE BENDING VOXEL 01

42

04.02 TEST CASE : FREI OTTO COLUMN

52

05 INITIAL METAL WIRE AND BENDING RESEARCH

55

05.01 BENDING AND WELDING RESEARCH

56

05.02 BENDING MACHINE RESEARCH

58

06 ROBOTIC ASSEMBLY

65

05.02 FABRICATION WORKFLOW

66

07 DESIGN DEVELOPMENT 3

71

07.01 DESIGN SKETCHES

72

07.02 TEST CASE : CHAIR

78

07.03 TEST CASE : TABLE

88

07.02 TEST CASE : COLUMN

90

08 WIREVOXELS DESIGN STRATEGY

95

08.01 STRUCTURAL OPTIMISATION

96

08.02 TEST CASE : FLOOR SLAB

104

08.03 TEST CASE : FLOOR SLAB AND COLUMN

112

09 FABRICATION DEVELOPMENT

117

09.01 METAL WIRE RESEARCH

118

09.02 CUSTOMIZED ROBOTIC BENDING

120

09.03 BENDING VOXELS : 1ST SKETCH VOXELS

124

09.04 BENDING VOXELS : SIMPLIFIED VOXELS

126

09.05 WELDING PROCESS

128

09.06 ASSEMBLING PROCESS

130

10 ARCHITECTURAL SPECULATION

133

10.01 ARCHITECTURAL PROTOTYPE 01

134

10.02 ARCHITECTURAL PROTOTYPE 02

144

10.03 CONSTRUCTION STRATEGY

150

11 PHYSICAL FLOOR SLAB 11.01 ASSEMBLY AND INSTALLATION STRATEGY

153 154

RESEARCH STRAND

INTRODUCTION

00.01 RESEARCH STRAND 00.02 MATERIALITY 00.03 PRECEDENT STUDIES 00.03 DIGITAL DESIGN AND FABRICATION DESIGN RESEARCH INITIAL DESIGN 01.01 INITIAL DESIGN : VOXEL 01.02 INITIAL DESIGN : TILE 01.03 CHAIR VOXELISATION AND TOPOLOGY STUDY

DESIGN DEVELOPMENT 03.01 INITIAL CURVES DEVELOPMENT 03.02 TEST CASE : CHAIR 04.01 METAL WIRE BENDING VOXEL 01 04.02 TEST CASE : FREI OTTO COLUMN 07.01 DESIGN SKETCHES 07.02 TEST CASE : CHAIR 07.03 TEST CASE : TABLE 07.02 TEST CASE : COLUMN

ARCHITECTURAL SPECULATION 10.01 ARCHITECTURAL PROTOTYPE 01 10.02 ARCHITECTURAL PROTOTYPE 02 10.03 CONSTRUCTION STRATEGY

COMNPUTATIONAL PROCESS

MATERIAL RESEARCH

FABRICATION RESEARCH

INITIAL RESEARCH

INITIAL FABRICATION

02.01 MATERIAL TEST

02.02 CASTING AND ASSEMBLY

09.01 METAL WIRE RESEARCH

02.03 FABRICATED CHAIR FABRICATION DEVLOPMENT

WIREVOXELS DESIGN STRATEGY 08.01 STRUCTURAL OPTIMISATION 08.02 TEST CASE : FLOOR SLAB VOXELIZATION

08.03 TEST CASE : FLOOR SLAB AND COLUMN

09.02 CUSTOMIZED ROBOTIC BENDING 09.03 BENDING VOXELS : 1ST SKETCH VOXELS 09.04 BENDING VOXELS : SIMPLIFIED VOXELS 09.05 WELDING PROCESS 09.06 ASSEMBLING PROCESS

00 INTRODUCTION

00 INTRODUCTION

00.01 RESEARCH STRAND

MEIZI LI // SUPAKIJ HOMTHONG // DONGHWI KIM // ONYEE WONG //

WireVoxels proposes to fabricate building blocks out of robotically bent steel tubes. These blocks are composed of a limited number of serialised steel elements and share the same connection system, which allows for efficient assembly.

The combination of the topology or body-plan of each building block can change in response to its local structural condition. This results in continuously differentiated, yet highly optimised structures, both in terms of structural performance and fabrication logistics.

08

This research challenges the limitation of “SPACE FRAME” in architectural design and fabrication methodology with computational design and robotic production. When it comes to computational design, the project performs based on “Voxels” and “B.E.S.O.” (Bidirectional Evolutionar y Structural Optimization). In terms of robotic production, it works with robots, bending and assembling metal wires.

Voxel is a computer-based modelling medium representing a value on a regular grid in thre -dimensional space. Each voxel contains a unique 3D datum, and when the method to combine this data is provided, the overall voxel space is read as one structure.

B.E.S.O. (Bidirectional Evolutionary Structural Optimization) is the structural optimization to produce the best or most appropriate design according to the objective for the structure. This could mean finding the optimum material, shape, size, thickness, temperature or weight for the structure, under the expected condition.

As a consequence, this project is attempting, at first, to present the developments of “SPACE FRAME” in architectural fields nowadays and to define the merits and demerits of the metal wire related to the space frame in recent architectural design. Furthermore, it deals with how we can develop the space frame by metal wires especially when it comes to the computational design and fabrication in the methodology of contemporary design.

09

00 INTRODUCTION 00.02 MATERIALITY

3D Printed Architecture

In recent years, 3D rapid prototype machines have become mainstream. Par ticularly, 3D Printers have been in the spotlight, not only for business uses but also for individual hobbies and D.I.Y at home. However, 3D printers that use plastic extrusion expose a number of limitations. This is due to the machine only being able to make layers of thin lines, and during the process, when it makes a line in midair, this condition is not suitable for making a straight line. The plastic material of the 3D printer is too weak to make a single line in the air. Moreover, in reality, since it takes time for the line to solidify and due to the gravity, the extruded single line cannot be a straight line. It can be bent and broken easily. In addition, the machines require suppor ting base when printing the object which could lead to wasting a large amount of material, whilst on top of that, slowing down the process as well.

Limitation of Plastic Exturding

10

Metal Wire Frame

When we consider these problems at hand, we search for a better option and if we can make a strong single line in space rather than volumes, we can also imagine a new kind of printing method which can compensate the defects of 3D printers. As a result, when we use metal wires, we can solve the problems simply. This is because the metal wires are strong enough to make a single thin line in a space. Moreover, thanks to advanced robotic technologies or programs, we are able to calculate ever y bend points of the metal wires to make a specific geometr y to match what designer wants, and this allows the creat ion of interesting components, voxels or modules ver y rapidly and precisely.

Fur thermore, when it comes to the Architectural industr y, this can give a sensational impact on, not only the construction field but also design methodologies which are based on the modular system.Due to the project aiming to deal with lines more than masses, reducing weight and volume of geometr y by tr ying to create a continuous line inside a unit (voxel) was focused on, avoiding either fabricating or casting heavy materials. Not only this aim, but the project also envisioned ideas to the next step in creating metal wire bending that could give the project more benefits compare to casting or plastic extruding which may have some errors, problems of structural reinforcement in larger scale and cannot be reused and recycled.

Therefore, this research aims to explore the journey of fabrication from continuous to discrete and how efficient it can be if we use robots not only in the fabrication but also in the assembling process compared with manual assembling as well as to search how to apply to the architectural design.

Wire Frame Architecture

11

00 INTRODUCTION

00.03 PRECEDENT STUDIES

Roof Construction for Aircraft Hangar, Konrad Wachsmann, 1951-1953

Heydar Aliyev Center, Zaha Hadid, 2007

Clouds of Venice, Supermanoeuver, 2015 12

In fact, the metal wire work is not new thing in the architect u r a l f i e l d . I n t h e 2 0 t h c e n t u r y, m a n y m e t a l w i r e b u i l d i n g s had not only demonstrated beauty but also the successful profit of the metal wire, exampled by amazing architects who pursued ‘ High-tech Architecture’. Many people have suppor te d t h e m e t a l w i re s t y l e i n a rc h i t e c t u re f i e l d s b e c a u s e o f i t s beautiful of appearance but also its prosperous economics for the construction and maintenance.

A space frame by Buckminster fuller, an excellent pioneer, is economically feasible and has a high durability and productivity. However, it has tended to show how homogeneous the pattern and shape as design outputs can be, which may not be the Modernists’ one. The buildings by Zaha Hadid, that show another level of the use of space frame show heterogeneous shapes. Never theless, since the ever y beam is different, it takes a longer amount of time and expenditure in fabrication and assembling. Fur thermore, the project ‘Cloud of Venice’ where the most advanced techniques was applied in terms of wire fabrication, attempted ever y components to unitization. However, it did not overcome the repetitive, homogeneous shape like Buckminster fuller ’s one. This image compares and show the limitation of the recent space frame structure.

Thus, this research aims in achieving the method to make it possible in building a heterogeneous form structure as Zaha Hadid has in her architecture whilst fabricating metal wire efficiently like Buckminster fuller at the same time. This is the reason why this research uses the metal wires and combinatorial voxels.

13

00 INTRODUCTION

00.04 DIGITAL DESIGN AND FABRICATION

Combinatorics Voxel

Data

Combination of Voxels

14

3D Voxels work in same way in that each voxel contains uniqe 3D data, when the method to combine this data is provided, overall voxel space is read as on structure.

These imgages show that the combination of voxels can make different aggregations and patterns when they connect with each other. This project is not only concerned about continuous printability, but also interested in continuous bending, assemblage and reversibility. To achieve the metal wire bending process, this project examines and investigates on searching and generating algorithms, as well to find suitable results in design optimization.

15

00 INTRODUCTION

00.04 DIGITAL DESIGN AND FABRICATION

STRUCTURAL OPIMIZATION

When we think not only about the interest of making the shape and forms but also in terms of architectural spectrum, we can make some questions about the appropriateness of the decision of the structural shape and form. Simply speaking, how we can make a heterogeneous structure. Not only just focusing on heterogeneous shapes for the heterogeneity, but for having the natural appropriateness when we design the columns, slabs and so on. Moreover, if we can create a natural heterogeneous structure by the structural analysis or interpretation without any intention, it provides a natural structure solution, and can be connected with the logic and advantages what the voxel have, for example, economics, simplicity and rationality.

Therefore, among many methods of structure optimization, the B.E.S .O. (Bidirectional Evolutionar y Structural Optimization)is the most suitable solution for metal wire structure.

The wire frame is most appropriate and also it is the proper parametric design material which can be changeable under the variable condition. Left also shows a cantilever after applying the “BESO for Beams”-component on it. The algorithm works on beam and truss elements only.

Cantilever with initially regular mesh after application of the ”BESO for Beams”-component

SUPPORT

MANAGEMENT OF B.E.S.O.

As a consequence B.E.S.O is the most suitable structure optimization for metal wire structure. Fur thermore, since the interpretation of B.E.S.O. provides an open ended outcome, it can also appropriate for the combinatorial voxels. In other words, although B.E.S.O. analyses the same structure, it provides diverse outcomes [Fig_13] for designers which can be chosen by the density and thickness what the they want. For instance, In the Left imgae, B.E.S.O. provides diverse optimization percentage, and the designer can decide which percentage of optimization is suitable for them among the variations. In addition, in the process of optimization, omission and replaceability of the segments are happened. For instance, each two segments can be replaced into one thicker segment like the phenomenon in the image. To deal with this change, we will use the overlapping strategy 30 %

in this project. A metal wire can be thinker when they are overlapped to each other to make a strong structure.

50 %

75 %

17

01 INITIAL DESIGN

01 INITIAL DESIGN

01.01 INITIAL DESIGN : VOXEL

01.01.01 2D COMBINATORICS RESEARCH

Type1

Type2

Type3

Type4

Type5

Type6

Type7

Type8

20

ossed suface & pattern

4 components 3 components 2 components 1 component

Folding surface

4 components in a voxel 4 Components in a Voxel

21

01 INITIAL DESIGN

01.02 INITIAL DESIGN : TILE

SELECTED VOXELS

From our experiments in finding posssible components and voxel, we have tried to create many different types in terms of design, components can be lines, surfaces, masses and so on which can express the discreteness, heterogeneity, combinatorics mereology as well as has some possibilities to be assembled easily.

Searching possible geometries

Connections

22

Sample aggregation

Subtracted-triangular shape

Proposal connectors

23

01 INITIAL DESIGN

01.03 CHAIR VOXELIZATION & TOPOLOGY STUDY

Chair prototype

Voxelized chair

Stress analysis

Fabricatd chair

24

Aggregation of the chair

25

02 INITIAL FABRICATION

02 INITIAL FABRICATION 02.01 MATERIAL TEST

Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.

In the casting process, we tried plastic, plaster, wax and silicone as materials. For mould material, we used silicone and 3D printed mould.

- cheap - high strength - heavy - time consuming plaster

- light weight

The advantage of casting is that it can achieve very high precision and some materials take a very short time to solidify. The problem is due to it is solid, so sometimes weight problems cannot be solved.

- fragile ABS filament

- flexible - high cost - none-recyclable silicone

- cheap - easy to cast - fragile - easy to melt wax

- solidify quickly - high strength - high cost plastic

- high strength - translucent - heavy - high cost acrylic

28

Wax

Plaster

Silicone

Plastic

29

02 INITIAL FABRICATION 02.02 CASTING & ASSEMBLY

01

02

03

04

05

06

01

02

03

Aggregations

31

02 INITIAL FABRICATION 02.03 FABRICATED CHAIR

32

33

03 DESIGN DEVELOPMENT 1

03 DESIGN DEVELOPMENT 1

03.0 INITIAL CURVES DEVELOPMENT

Solid plaster voxels are inefficient to fabricate. This is because that plaster are very heavy and it takes too much time to solidify, therefore we try to use the solid voxel as an invisible container which can contain curves inside.

Solid

Container

Curves in container

Plaster Bricks

Tranformation

36

HOW TO PRINT WITH CONTINUITY : Graph theory

In mathematics graph theory is the study of graphs, which are mathematical structures used to model pairwise relations between objects. A graph in this context is made up of vertices, nodes, or points which are connected by edges, arcs, or lines.

Iteration 1

Iteration 2

Iteration 3

Printability

37

03 DESIGN DEVELOPMENT 1 03.02 TEST CASE : CHAIR

Low density chair

Medium density chair

High density chair

38

04 DESIGN DEVELOPMENT 2

04 DESIGN DEVELOPMENT 2

04.01 METAL WIRE BENDING VOXELS 01

04.01.01 2D COMBINATORICS LOGIC

The project started from creating a solid and unique geometry and then aim to reduce weight and volume of it by turning the solid unit to be a mere container, and tried to create a continuous line inside, to avoid either fabricating or casting heavy materials. With the first developed idea that we changed from plaster casting to plastic extruding. Consequently, the result reflected more interesting and reasonable, and on top of that the project can be solved the overweight problem. Not only this discovery but the project also be envisioned to the next step that is creating metal wire bending that could give us more benefit compare to plastic extruding which may have some errors, problem of structural reinforcement in larger scale and cannot be reused and recycled.

Integrating a continuos line into a voxel is our basic idea to acheive the basic concept of both continuity and discreteness, then the project is developed these concept under possibilities of both continuous bending and assembling which involving with welding process.

These diagrams show the initial idea that how can we analyse the possibilities of growth in the basic voxel.

And also shows the methods we chose to start and optimise our design to acheive our goal as explained.

42

Voxels logic

Multi-scale

Using point

Using lines

Using lines combination

43

04 DESIGN DEVELOPMENT 2

04.01 METAL WIRE BENDING VOXELS 01

04.01.02 2D COMPUTATIONAL PATTERN RESEARCH

04.01.03 3D COMPUTATIONAL LOGIC

6

3

2

1

4

Connecting point

5

Connecting line

Rotations

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

45

04 DESIGN DEVELOPMENT 2

04.01 METAL WIRE BENDING VOXELS 01

04.01.04 3D COMBINATORICS LOGIC

41 Connections continuity closed loop overlapping

46

04.01.05 PATTERN RESEARCH

Flower

Insect

Star

Butterfly

Alien

Fox

47

04 DESIGN DEVELOPMENT 2

04.01 METAL WIRE BENDING VOXELS 01

04.01.06 DIFFERENT VERSIONS OF LINES

Version 1

Version 2

Version 4

Version 3

Top view

Front view

2L

2L

2L

Perspective view

1 control point / same con.length

1 control point / increase 1 length

1 control point / increase 2 length

3 control points / same con.length

48

04.01.07 DIFFERENT VERSIONS OF LINES AND CHAIRS

Version 1

Version 2

2L

1 control point / same con.length

1 control point / increase 1 length

Version 3

2L

Version 4

2L

1 control point / increase 2 length

3 control points / same con.length

49

04 DESIGN DEVELOPMENT 2

04.01 METAL WIRE BENDING VOXELS 01

04.01.08 OVERLAPING LOGIC

Low Stress

High Stress

Highest Stress

Original line

Double lines

Triple lines

Chair voxelisation & Stress Analysis

50

51

04 DESIGN DEVELOPMENT 2

04.02 TEST CASE : FREI OTTO’S COLUMN

Our anticipation in architectural scale is inpired by columns in The Stuttgart train station which is designed by a famous architect Frei Otto. It is said that “The structure and the “lighting cones“ connect the platform level with the square and park above. Varied and broad views along with the elegance of the supporting structure give the station its unmistakable identity. The form of the modular shell supports is based on the reversed-suspension model” (Architect : Frei Otto, 2009-2019)

52

05 INITIAL METAL WIRE & BENDING RESEARCH

05 INITIAL METAL WIRE & BENDING RESEARCH 05.01 BENDING & WELDING RESEARCH

05.01.01 BENDING FACTORS

Understanding Springback

Factors that control or influence the success of a bending operation Thickness

Actual Radius

Bending Angle

- Thickness The thicker the material, the less the springback.

- Tolerance

Bent Angle

Bending Radius

When metal is thicker or thinner, it is squeezed less or more in the bending operation, respectively.

- Size The size of the inside bend radius also affects the amount of springback. The larger the bend radius, the more the springback.

- Speed The speed at which the bending takes place also affects springback. Generally, faster forming speeds reduce the amount of springback.

- Grain direction The grain direction is established during the metal rolling process. Bending with the grain gives a different result than bending against it.

The two reasons of Springback

- Friction

l. displacement of molecules within the material ll. stress and strain.

During bending, the metal is forced between the lower die section and the forming punch. If the clearance between these two sections is less than the metal thickness (as it usually is), intense friction is created.

Tensile Stresses

Compressive Stresses

0

Neutral Axis

As the material is bent, the inner region of the bend is compressed while the outer region is stretched, so the molecular density is greater on the inside of the bend than on the outer surface.

The compressive forces are less than the tensile forces on the outside of the bend, and this causes the material to try to return to its flat position

56

05.01.02 WELDING METHODS

GMAW or Gas Metal Arc Welding More commonly called MIG welding this welding type is the most widely used and perhaps the most easily mastered type of welding for industry and home use. The GMAW process is suitable for fusing mild steel, stainless-steel as well as aluminium.

MIG Welding l Advantages - Most widely used - Easily mastered type

Suitable materials - Mild steel - Stainless steel - Aluminium

GTAW or Tungsten Inert Gas TIG welding is comparable to oxy acetylene gas welding and needs a lot more expertise from the operator. Employed for carrying out high-quality work when a superior standard of finish is needed without making use of excessive clean up by sanding or grinding.

TIG Welding l Advantages - Need a lot more expertise to operate - High-quality of work

Suitable materials - Mild steel - Stainless steel - Aluminium

Arc Welding or SMAW Generally known as stick or arc welding. Arc welding is the most basic of all welding types, is easy to master in a home welding situation.

Stick welding can be used for manufacturing, construction and repairs, very much well suited for heavy metal size 4 millimetres upwards.

Thinner sheet metals and alloys are usually more suited to the mig welding types.

Stick or Arc Welding l Advantages - Most basic of all types - Easily mastered type - Suited for heavy metal size 4 mm. upwards.

Suitable materials - Mild steel - Stainless steel - Aluminium

Gas or Oxy Acetylene Welding Not used as widely for general welding of mild steel. Consists of mixing oxygen and acetylene gas to greate a flame capable of melting steels.

Mostly used today for maintenance work and gas metal cutting. Also common for brazing softer metals such as copper and bronze. Can also be used for welding delicate aluminium parts such as refrigeration pipes.

Gas or Oxy Acetylene Welding l Advantages - Not widely used - Mostly used for maintenance

Suitable materials - Copper - Bronze - Aluminium

57

05 INITIAL METAL WIRE & BENDING RESEARCH 05.02 BENDING MACHINE RESEARCH

05.02.01 BENDING MACHINES STUDIES

About the bending part of this machine is ideal for difficult job situations and fatigue, thanks to its one-block body and excellent mechanical characteristics. The bending disk can be rotated in two ways - clockwise and anti-clockwise. It comes with all the essential characteristics needed for normal bendings.

The excellent design of the machine and the modern technology embedded in it promises optimal performance while utilizing low power. Here are some of the accessories used with this machine - tool set for stirrup bending speed variator, double foot pedal, selector panel and special tooling for spirals

Initial design sketches

Industrial Bending Machine

58

05.02.02 CUSTOMIZED MANUAL BENDING MACHINE

Working Process

59

05 INITIAL METAL WIRE & BENDING RESEARCH 05.02 BENDING MACHINE RESEARCH

05.02.03 CUSTOMIZED ELECTRONIC BENDING MACHINES

Z AXIS ROTATING WIRE HOLDER EXTRUDER WHEEL BENDER WIRE HOLDER BEARING BEARING

MOVEMENT

STEPPER MOTOR

STEEL ROD

SOLENOID BENDER WHEEL

STEPPER MOTOR

SUPPORT SUPPORT

STEEL ROD

DRIVER

ARDUINO BOARD

BREAD BOARD STEPPER MOTOR 23

60

TOP VIEW BENDING

EXTRUDING

ROTATING

ELEVATION

61

05 INITIAL METAL WIRE & BENDING RESEARCH 05.02 BENDING MACHINE RESEARCH

ELECTRONIC BENDING MACHINE

06 ROBOTIC ASSEMBLY

06 ROBOTIC ASSEMBLY

06.01 FABRICATION WORKFLOW

06.01.01 ROBOTIC SUPPORTED EXTRUSION

Our developed supported extrusion method gives a new and creativity way to explore a new method of wire bending.

This methods allows, thanks to the high flexibility but strong enough material, to bend different scale which also is a selfsupport structure based pieces. This wire created in the idea of using copper cored wire and the logic of spatial printing, the process of bending the wire is similar to the method of spatial 3D printing. Once the pieces was bent, it will put it on the base which is custom make for the KUKA ABB robot.

The robot will start to assemble thought the 3/2 pneumatic solenoid valve with two-finger parallel gripper. The result of this, is an innovative piece of architecture with structural performance, and translucent effect achieved.

66

06.01.02 TOOLS DESIGN : PARALLEL GRIPPER

The pneumatic solenoids are controlled by a PLC(Programmable Logic Controller) which energizes said devices to open or close a valves connected to piping systems.

The PLC has been programmed by Grasshopper order to send power to the Solenoid when cer tain variables are met (temperature, pressure,flow rate, etc.).

Attachment with Robot

These variables are themselves fed back by wire to the PLC from Transmitters in the field (Temperature Transmitters or TT, Pressure Transmitters, Flow Transmitters).

Connector

3/2 way Pneumatic Solenoid Valve

Two-finger Parallel Gripper

Maximum Open Distance: 4mm

67

06 ROBOTIC ASSEMBLY

06.01 FABRICATION WORKFLOW

06.01.03 ASSEMBLY PROCESS

step 1

step 16

step 31

step 4

step 19

step 34

step 7

step 22

step 37

step 10

step 25

step 40

step 13

step 28

step 41

06.01.04 WORKING AREA

Maximum Working Area

Base

06.01.05 CHAIR ASSEMBLY

001

002

003

004

005

07 DESIGN DEVELOPMENT 3

07 DESIGN DEVELOPMENT 3 07.01 DESIGN SKETCHES

07.01.01 2D PATTERN STUDY

Initial design sketches We try to understand how can we design the simple discrete lines which can establish the interesting patterns.

Also, the lines we created will have possibilities to generate different densities or directions.

Our ambition is to acheive high quality of design outcomes which can be integrated with effectively simple metal wire bending processes.

Initial pattern study Alignment and parallel spacing = Arrangement Turning angle = Changing directions

135’

135’

135’

72

Started from 1 line

Defines some 2D design languages

L- shape

Linear

Diagonal

73

07 DESIGN DEVELOPMENT 3 07.01 DESIGN SKETCHES

07.01.02 Tranlates initial sketch into voxels

L- shape

Linear

Diagonal

74

07.01.03 Pattening and Stabilizing

L- shape

Linear

Diagonal

Compression Tension

75

07 DESIGN DEVELOPMENT 3 07.001DESIGN SKETCHES

07.01.04 CONNECTIONS

Type 1

Type 2

Type 3

Type 1 - Type 1

Type 1 - Type 2

Type 1 - Type 3

Type 2 - Type 2

Type 2 - Type 3

Type 3 - Type 3 76

07.01.05 AGGREGATIONS

Type 1

Type 2

Type 3

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07 DESIGN DEVELOPMENT 3 07.02 TEST CASE : CHAIR

07.02.01 REFERENCES OF METAL WIRE CHAIR

Diamond Chair (Harry Bertoia, 1950)

Pylon Chair (Tom Dixon, 1992)

Parabola Chair ( Carlo Aeillo, 2013)

The structure of the “Diamond Chair” clearly separates the different functions of the chair: the transparent wire shell is bent out of a quadratic lattice into an organically shaped diamond like a net frozen in space, and the base of round iron embraces it like a polished diamond.

Bertoia considered his furniture to resemble his sculptures and explained: “In sculpture I am primarily interested in the relationship between form and space and the characteristics of the metal. In chairs many functional problems have to be solved first... but basically chairs are also studies in space, form and metal. On close inspection it becomes clear that they are mostly made up of air…. Space flows right through them.”

Tom Dixon’s “Pylon” chair is constructed of thin steel rods which, when welded together, give the structure sufficient strength to support even large people. It is essentially a desk or dining chair, though can be used for occasional purpose too.

Parabolas were first implemented in architectural and product design in the 1950s (see Le Corbusier’s Philips Pavilion or anything by the engineer Pier Luigi Nervi), when designers were free to move past the Platonic, rectilinear, and by then historicized high Modernism of the ‘20s. Aiello’s use of chrome finishes draws on the Modernist chairs, but it also nods to diner design and Ford T-birds.

Pylon chair is manufactured entirely by hand.

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07.02.02 VOXELIZED CHAIR

160 mm

28 Voxels

Stress analysis

Voxelisation

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07 DESIGN DEVELOPMENT 3 07.02 TEST CASE : CHAIR

07.02.03 DEFINED DESIGN CONSTRAINTS

ALIGNMENT

BRACING

OVERLAPPING

ELONGATION

80

07.02.04 VOXEL CATALOG

A1

A6

B1

B5

A2

A7

B2

B6

B3

B7

A3

A4

A8

B4

A5

81

07 DESIGN DEVELOPMENT 3 07.02 TEST CASE : CHAIR

07.02.05 ASSEMBLY STRATEGY

82

A0

B0

A0

B1 A1

A3

B4

A5 B1

A2 A3

A4 A3

B0 B1 A6

83

07 DESIGN DEVELOPMENT 3 07.02 TEST CASE : CHAIR

84

85

07 DESIGN DEVELOPMENT 3 07.02 TEST CASE : CHAIR

07 DESIGN DEVELOPMENT 3 07.03 TEST CASE : TABLE

Geometry

Stress analysis

Voxelisation

88

89

07 DESIGN DEVELOPMENT 3 07.04 TEST CASE: COLUMN

Geometry

Stress analysis

Voxelisation

08 WIREVOXELS DESIGN STRATEGY

08 WIREVOELS DESIGN STRATEGY 08.01 STRUCTURAL OPTIMISATION

08.01.01 BESO & CROSS-SECTION OPTIMISATION METHOD

When it comes to the structural optimization process (B.E.S.O.) , at first, we should decide the size of slab and the location of loads and suppor ts. In this research, we set 4mx4m the size of slab. After that, we set a proper span of grid to deal with the variation of el ements come from the structure analysis. In other word, the designers can set the size of the grid according to the size of voxel they want to make.

The next step is the standardization of the vectors in each grid that come from after the structure analysis (B.E.S.O). Since B.E.S.O. can provide multiple direction of vectors in each grid, the designer need to know the average value of the vectors in each grid to simplify and replace the vector with his voxels. Of course, the voxel th e designer wants to use should be designed to reflect the direction of vectors.

However, no matter B.E.S.O. provides complex multiple and complicated vectors, calculating average value of vectors in a grid is simple and easy to get when the desginer use computational program, then the vectors can be rever t to voxel easily.

Another advantage of BESO is that since the output should be datafication in the computer program, it is appropriate to use for computational logic as well Finally, based on the B.E.S.O. data, the structure can be generated automatically by computational process.

Cantilever with initially regular mesh after application of the �BESO for Beams�-component.

96

08.01.02 INITIAL FLOOR SLAB TOPOLOGY OPTIMISATION

2.80 m.

2.80 m.

01 : Floor plate

03 : Draws grids for strctural optimisation

load

load

support

load

02 : Voxelized floor plate (20 cm.x20 cm.)

04 : Sets initially support and load conditions

97

08 WIREVOELS DESIGN STRATEGY 08.01 STRUCTURAL OPTIMISATION

08.01.03 POSSIBLY STRUCTURAL ELEMENTS

Grid type

Type 1

Type 2

Type 3

100% structure

98

08.01.04 OPTIMISING CATALOG

Type 1

Type 2

Type 3

30%

50%

75%

99

08 WIREVOELS DESIGN STRATEGY 08.01 STRUCTURAL OPTIMISATION

08.01.05 GRID TYPE 1 PATTERNS FROM DIFFERENT LOAD CASES

support

support

support

30%

50%

75%

08.01.06 OPTIMISED COMPONENTS

Series of 2D line

135’ 135’

Creating 3D voxels by adding bracing lines

1

Inside

To neighbours

Voxel + bracing lines

2

3

4

101

08 WIREVOELS DESIGN STRATEGY 08.01 STRUCTURAL OPTIMISATION

08.01.07 GENERATIVE STRATEGY

Voxelized floor slab

Evaluating the vectors (Zoom-in 1x)

Evaluating the vectors (Zoom-in 2x)

Mapping with voxels (Zoom-in 2x)

Series of line inside the voxel

An example mapping in 3D

103

08 WIREVOXEL DESIGN STRATEGY 08.02 TEST CASE : FLOOR SLAB

08.02.01 COMPUTATIONAL LOGIC

support

Selected load case 75%

Voxelized pattern

Vector field

105

08 WIREVOXEL DESIGN STRATEGY 08.02 TEST CASE : FLOOR SLAB

08.02.02 MAPPING DIFFERENT TYPES OF VOXELS

1

2

3

4

107

08 WIREVOXEL DESIGN STRATEGY 08.02 TEST CASE : FLOOR SLAB

08.02.03 ADDING DESIGN CONSTRAINTS

Overlaping

Bracing

Elongation

109

08 WIREVOXEL DESIGN STRATEGY 08.03 TEST CASE : FLOOR SLAB & COLUMN

08.03.01 COMPUTATIONAL LOGIC

support

BESO structure analysis

Voxelized the pattern

Vector field

08.00.00 AAA

frame 01

frame 26

frame 51

frame 76

frame 101

frame 126

frame 151

frame 176

frame 201

frame 226

frame 251

frame 276

frame 301

frame 326

frame 351

frame 376

frame 401

frame 426

frame 451

frame 476

09 FABRICATION DEVELOPMENT

09 FABRICATION DEVELOPMENT 09.01 METAL WIRE MATETIAL RESEARCH

Excellent

Very cheap

Very cheap

11.40 / KG.

Mild Steel

Stainless Steel

Very cheap

Very expensive

37.00 / KG.

Gavanised Steel

18.80 / KG.

Very expensive

Copper Coated Mild Steel

18.80 / KG.

Expensive

38.00 / KG.

Bronze

15.70 / KG.

Cost

Aluminium

Good

Good

Fair

Good

Good

Fair

Good

Fair

Good

Excellent

Good

210 GPA

200 GPA

Good

Heavy

8000

Heavy

7500-8000

Heavy

Heavy

860 MPA

760 MPA

760 MPA 210 GPA

120-210 GPA Heavy

8000

Weight

2500 KG./CU.M.

Light

Good

Good

7500-9000

Stress/Strian

70 GPA

Young’s Modulus

Fair

120 GPA

Poor

7500-8000

250 MPA

Strength

110 MPA

Poor

220-760 MPA

Easily Formed

118

M ATERI AL The material also is one of the impor tant par ts of the research.

Due to the first experiment we used 1.6 mm cooper wire for the be nding material, although the outcome looks nice with the lightweight structure but the strength is not strong enough for the suppor ting as a chair for people to sit.

At the second trial, It used the 6mm mild steel rod bar which still maintain the lightweight outlook and not only stable as a chair but also strong enough for suppor ting itself as a column, ceiling, and platform. According to the weight of a 23 voxels cha ir is still not that heavy. However, using 6mm mild steel has a problem which is the problem of spring back. Each steel has its stress and strain. Besides, the displacement of molecules within the material also will affect the final result after bending the steel rod.

Thickness, grain direction and size of the material, tolerance, bending speed and friction, these factors also will affect the control or influence the success of a bending operation.

Since the material is bent, while the internal area of the rod is compressed, the external area will be pulled, so that the molecular density of the inner par t is larger than the outer sur face. The compression force is less than the outer of bending tensile force, which causes the material back to the origin position as its flat.

As steel rod bending study ( figure ), we found out that the spring back effect from the range of 5 to 10 degrees. Therefore, we also have to add the greater degree more than the original one after expor ting the data to bend the steel rod.

Preventing the spring-back effect, make sure the outcome is less tolerance happen.

119

09 FABRICATION DEVELOPMENT 09.02 CUSTOMIZED ROBOTIC BENDING

09.02.01 TOOLS DESIGN

In the robotic bending process,we focus on how to fabricate metal wires precisely so we paid much attention to the design of the whole bending machine system. To avoid the bar getting away from the bending axis, we set a linear bearing connected to the gripper for feeding and rotating. Moreover, the design of the bending pin can reduce a lot of friction because during the bending process, the two cylinders for bending can always rotate freely. Finally, we achieve mass production, in three hours, we bent 150 pieces.

Feeding gripper Bending table & Bending gripper

Feeding gripper

Bending table & Bending gripper Mounting Plate Ball Bearing 698Z Roller Shaft

Hex Head M3 Bolt (15mm) Collar Roller Shaft Ball Bearing 698Z

Hex Head M3 Bolt (15mm) Table

Hex Head M3 Bolt (30mm)

Table

121

09 FABRICATION DEVELOPMENT 09.02 CUSTOMIZED ROBOTIC BENDING

09.02.02 TOOLS MAKING

Rotating bender

Preparation of robotic bending Up to now, the project had been invested two semesters as a total of five months, used a multi-use KUKA KR60 machine with 6-axis robot arm and the seat of 2 axis positioner table. The CNC bending device is used to customize the program for bending the 6mm mild steel rods of a three-dimensional shape.

Different purposes of the project require a separate attachment. In Wirevoxel used two grippers plus a bending device. One gripper is for extruding and rotating. And the other one is for holding the steel rod when it is bending. The preparatory work of this kind of precision attachment cannot be completed in a short time.

Before the bending project starts, it also spent at least two weeks for material research and made good use of the machine design to apply to the bending device design. The production process of the bender is also very time-consuming. From the design, export the file to waterjet for cutting the sheet steel plate as few pieces, and then welding, every step can not be taken lightly. It is because each tool design is extremely delicate and is only available in 6mm of steel rod bar. Slightest error occurs, such as gripper cannot be clamped the rod very precisely. If such a situation occurs which means the attachment is no longer applicable with the robot arm that is to be re-do it again for this project.

Gripper holder

Bending tools

122

Feeding part

Bending part

123

09 FABRICATION DEVELOPMENT

09.03 BENDING VOXELS : 1ST SKETCH VOXEL

09.03.01 SERIES OF LINE

Type 1B x 2 Type 1A Type 1C x 2 A

1 Type

Line type 1

2 1B x Type 1C Type

1C-m Type 2 1D x Type

Type 1D x 2

Voxel type 01 Type 2D Type 2C Type 2B x 3

Line type 2

Type

2A x

3

Type

2B x

3

Type

2C x

1

Type

2D x

Type 2A x 3

Voxel type 02 Type 2G Type 2H Type 2F x 4

Line type 2

Type

2E x

2

Type

2F x

4

Type

2G Type

2J Type

Type 2J

Voxel type 03

Type 2E x 2

2H

1

09.03.02 SERIES OF FABRICATED VOXEL

09 FABRICATION DEVELOPMENT

09.04 BENDING VOXELS : SIMPLIFIED LINES

09.04.01 SERIES OF LINE

Line type 1

Line type 2

Line type 3

Line type 4

126

09.04.02 SERIES OF FABRICATED VOXEL AND CHUNKS

09 FABRICATION DEVELOPMENT 09.05 WELDING PROCESS

07

09

06 10 08 01 11 03 04

02 06

05

12

01.2D bracing lines template 02.3D bracing lines template 03. Clamp 04. Wire cutter 05. Tape 06. Metal bent wire (6mm.)

07. Welding mask 08. Welding gun 09. Air suction switch 10. Mig welding machine 11. Welding rod 12. Gas 128

Welding As the voxel design which created a few simple discrete lines which can establish the interesting patterns.

These voxel line design including the coding design which KUKA need it to control its behavior to solve the ability to transcend traditional CNC tool, very accurate manufacturing claim.

The code was developed to analyze wirevoxels geometry, and digital data is converted into a series of benders and robot operation. The code will be dividing as a line and arc angle as geometry and recording data, such as length and orientation of each segment of the line.

Exporting the data as a series of KUKA Code for the robot and bender respectively. These commands are arranged to reconstruct the original digital geometry of the steel rod and bending movements of the robot.

The bent components will be masked and transported to the site where starts to be manually assembled and welded. Each voxel will have around 7-9 discrete lines will be welding it together. The custom made welding jig made by 6mm and 3mm MDF board will be used it once all the components ready for positioning. As part of this self-index component, each element against the member for precisely at the same time directing the subsequent positioning. Once in position, the lever instead of manual welding.

2D bracing lines welding

3D bracing lines welding 129

09 FABRICATION DEVELOPMENT 09.06 ASSEMBLING PROCESS

09.06.01 CONNECTORS

In addition, another big issue in met al wire voxel is a connection problem which can be the related to discreteness. To secure of discreteness in the project, this research should find the way how to connect voxels to each other. Welding could be a possible solution but it is not suitable for robotic in terms of an efficiency. (Beorkrem, 2012) Above all, when it comes to the discrete design, we should think about the usefulness and advantage of the discrete design. Therefore, a connectors such as a clamp, a joint and a stainless rope can be a solution in terms of connection. Of course, it allows easy assembling and disassembling process when welding cannot. It is a positive option for the discrete design as well. This image is the test of the connection by a stainless steel rope.

Wire Connectors

130

In this line of thought, we should think about why the discreteness impor tant in robotic fabrication? First of all, in this research, we use the combinatorial voxel as mentioned earlier. Since voxels should be changed and substituted when th ere is need for design and fabrication, the voxels should be flexible and reversible. (Iwamoto, 2009) Despite of continuity in a whole wire frame structure, each discrete voxel in the structure should be flexible and easy to assemble to make heterogeneous shapes. In truth, discrete voxels allow this perfo rmance ver y well. Secondly, for robotic fabrication and assembling, the robot can fabricate products automatically and efficiently when they have a specific module system. A voxel can be a kind of discrete module which can be fabricated by th e robot. It can also be grabbed or ho ld onto a proper size by robotic gripper. As a consequence, discrete voxels naturally of fer these managements in right way. In other words, our ambition is to achieve this flexibility and changeable in the combinatorial voxels and making the heterogeneous shape after all.

Stainless Steel Rope Connection

Assembling process

131

10 ARCHITECTURAL SPECULATION

10 ARCHITECTURAL SPECULATION

10.01 WIREVOXELS ARCHITECTURAL PROTOTYPE 01

Load & Support

Voxelize

Tension

Compression

Multi-scale

Mapping

10 ARCHITECTURAL SPECULATION

10.01 WIREVOXELS ARCHITECTURAL PROTOTYPE 01

10 ARCHITECTURAL SPECULATION

10.01 WIREVOXELS ARCHITECTURAL PROTOTYPE 01

10 ARCHITECTURAL SPECULATION

10.02 WIREVOXELS ARCHITECTURAL PROTOTYPE 02

In conclusion, as mentioned earlier, from space frame to the recent robotic metal wire has limitation in terms of homogeneity and efficiency. To overcome the limitation, we have researched about the contemporary design paradigm and explore the recent design tendencies in terms of metal wire fabrication. The challenge was how we can develop the simple voxel but not be heterogeneous after all when they are aggregated each other. Therefore, we used metal components based on the combinatorial voxel and B.E.S.O. with the computational design methodology and robotic fabrication.

As a result, this project demonstrates the possibility of not only developments of the traditional space frame but also inventing architectural system that can generate space by the computational design and robotic bending and assembling. This methodology could apply to the architectural situation in the near future.

145

10 ARCHITECTURAL SPECULATION

10.00 WIREVOXELS ARCHITECTURAL PROTOTYPE 02

10 ARCHITECTURAL SPECULATION

10.00 WIREVOXELS ARCHITECTURAL PROTOTYPE 02

10 ARCHITECTURAL SPECULATION 10.03 CONSTRUCTION STRATEGY

The use of digital design and digital fabrication systems are growing, even more than the gantry positioning system or cartesian coordinate robot, because they have the advantage which is the size and flexibility. It is coinciding with the changeover, cartesian coordinate robot absence of adaptability and agility, single-function, constraint workspace and high maintenance costs. Because of the emergence of new tools, the old operating system will be abandoned. It is coinciding with the changeover, cartesian coordinate robot absence of adaptability and agility, single-function, constraint workspace and high maintenance costs. Because of the emergence of new tools, the old operating system will be abandoned.

The architectural speculation approves the strategy to the large scale as a building. The strategy will fabricate kit-off parts off site (similarly to prefabrication). The in-house fabrication will be used the technique of robotic assembly and robotic welding at the same time for a few pieces of voxels.

The mass of the production can be finished in a short time. Then ship the parts of voxels with a container as a positioning jig. No matter assembly by robot or human which also can be more convenient and efficient. The whole workflow is providing a strong argument for the future development of robotics platform of digital manufacturing.

The robotic assembly and robotic welding can be worked at the same time.

It does not restrict with each other. In the experiment, robotic assembly is used as a case study in industrial-based traditions that can be augmented using contemporary robotic technologies. After having developed viable robotic workflows for free-form welding and assemble, we would like to incorporate into the parametric design, export the location data input, and visual user feedback to allow for more collaborative approaches to robotic assembly. Building collaborations in robotic would allow for more robust systems to support truly collaborative work in high-skill domains. Like the diagram of the future generation of fabrication criteria.

150

Prefabricarion - Robotic assembly and welding at the same time

Transport the voxel pieces to the construction site

On Site Assembly

151

11 PHYSICAL FLOOR SLAB

11 PHYSICAL FLOOR SLAB

11.01 ASSEMMBLY AND INSTALLATION STRATEGY

3.90

LOAD

LOAD

3.90

SUPPORT

LOAD

LOAD

01 FLOOR SLAB DIMENSION

03 VOXELIZED PATTERN BIG : 30 CM. SMALL : 15 CM.

02 OPTIMISED PATTERN

04 GENERATED PATTERN WIRES THICKNESS : 6 MM.

154

BIG VOXELS

SMALL VOXELS B-40-a Up - Dn

UPPER LAYER

B-40-b Up - Dn

B-40-c

B-40-d

Up - Dn

Up - Dn

LOWER LAYER

07 CODING STRATEGY

05 SPLIT LEVEL FOR OVERLAPED CONNECTION GAP : 6 MM.

A

1.50

2.40

B

C

D

1.50

0.90

E

1.50

2.40

0.90

1.50

1.50

1.50

06 PARTS & HANGING POINTS

08 CODED & REMOVED EMPTY VOXELS

155

11 PHYSICAL FLOOR SLAB

11.01 ASSEMMBLY AND INSTALLATION STRATEGY

A

1.50

2.40

B

C

D

1.50

0.90

1.50

2.40

0.90

1.50

1.50

E

1.50

B

A

E

C

D

156

Information Venue : Bpro show 2016 Slab size : 3.90x3.90 m.

Number of big voxels (30 cm.) : 71 Voxels Number of small voxels (15 cm.) : 235 Voxels Hanging points : 5 points

157

11 PHYSICAL FLOOR SLAB

11.01 ASSEMMBLY AND INSTALLATION STRATEGY

A PART OF PHYSICAL FLOOR SLAB

158