Optical-Structural Fusion by mimsrahin

ARCHITECTURAL DESIGN RC8

Ainaini RAHIN Mengyan SUN Jianfei LYU Studio Kostas Grigoriadis

Optical-Structural Fusion

in a Continuously Graded Building Envelope

Optical-Structural Fusion

in a Continuously Graded Building Envelope

TEAM

Mengyan SUN Jianfei LYU

Ainaini RAHIN

TUTOR

Kostas Grigoriadis

Research Cluster 8 2017 - 2018

Architectural Design

The Bartlett school of Architecture University College London

CONTENTS 01 PROJECT BACKGROUND -131.1 Foreword -151.2 Studio Brief -171.3 Project Statement -19-

02 PROJECT INTRODUCTION -2103 PROJECT DESIGN -373.1 Digital Design -393.1.1 Glass panel design -453.1.2 Metallic supporting structure (metallic frame) design -613.1.3 Point-support device (spider) design -673.1.4 Particle Generation -117-

3.2 Fabrication -199-

APPENDIX -301-

Digital Simulation- Grasshopper -303Digital Simulation- Real Flow -315Material Research -346-

CHAPTER 01

PROJECT BACKGROUND

CHAPTER 01 PROJECT BACKGROUND

FOREWORD The basis of this research is to identify the relationships between

digital fluid simulation technology and Architectural Design. Computational Fluid Technology, in relation to the building design, espe-

cially in terms of material studies is important in producing the best

architecture product. This research will be focusing on the production of the multi-material of metal and glass by using the fluid simulation process in the implementation of the building skins. Computer Fluid

Simulation Technology been used to provide the greater efficiency and higher standards that exploit particle systems in connection with one component of the structure and the skins of the building rather than having it separately.

The overall image appears that simulating fluid digitally is almost more different than it is from simulating it traditionally. The first phase of the

research involves the background and usage of digital fluid simulation and the traditional way of simulating fluid by using quantitative re-

search method. This will be done by comparing the digital simulation

and the traditional fluid simulation method measuring variables, theories and hypothesis in aspects of time, costs, parameters and accu-

racy. Upon examination of these methods, we identify the issues and challenges in producing the best outcome for the project. Through

showing the importance of synchronising the traditional method and

digital way of simulating the fluid and fabricating the FGM component in a building skin context, the research will be highlighted solution to

overcome the issues and how the revolution of digital fluid technology effects the paper based production in Architectural Design.

CHAPTER 01 PROJECT BACKGROUND

STUDIO BRIEF Research Cluster 8

The Imminent Reality of Multi-Materiality Tutor: Kostas Grigoriadis The assimilation of graded materiality in architecture promises a

fundamental shift in how elements come together, opening up a

new understanding of constructs as continuous fields, consisting of

diverse materiality varied on a local level. Research Cluster 8 explores

new procedures for designing and building with material gradients to match the anticipated, radical developments in manufacturing and construction.

The first part of these explorations concerns the attempt to assimilate graded information digitally and to target the distribution and engineering of digital sub-materials to meet aesthetic, structural,

and functional criteria. The second part is to physically manufacture graded elements or full-scale constructs. Research Cluster 8 creates

prototypes and structures that are more than just a collection of individual parts, initiating a new type of architecture for the future.

CHAPTER 01 PROJECT BACKGROUND

PROJECT STATEMENT Functionally Graded Material The development of the skins of the building are becoming ever more complex in Architecture and construction industries. Rapid

manufacturing utilised the application of different material as building structure. The ability and momentum for a development involvement sources in practice and technologies. It is effected economically and

environmentally in so many ways. The fabrication forms of the material, its morphological and qualitative changes have ever been characteristic of the social and cultural endeavours of the period, as well as of its technical standards.

Furthermore, fluid simulation systems in architecture was set up in

such a way to help the solid object knuckle under a continuous modi-

fication of material stiffness for a better performance. In result, a good fabrication method would contribute in cutting down the cost and

increase the production of environmental friendly materials. With the

assistance of Computational fluid dynamics technology, multi-materi-

als methods could be utilised to provide greater efficiency and higher standards that exploit the particles systems in connection with one

component of structure and the building skins rather than having it

separately. With the existing fluid and dynamics simulation tool in the market, we were able to develop a gradated structure and material

properties to achieve an outcome and also as method of expanding the creativity.

This research is focusing on the analysis of how the multi-material

simulation influencing the fabrication method traditionally and digitally. The hierarchy of the research starting with comparing the history

the history of the fluid based simulation that has been used by some architects in developing their projects in architecture. The diagram below shows the comparison between the traditional and digital thinking.

CHAPTER 02

PROJECT INTRODUCTION

OPTICAL-STRUCTURAL GRADATION In this research we are focusing on the functionally graded material.

Throughout the research we have developed the design by the implementation of topology optimization. The starting point from the early stage was from the spider connection component that attached the glass pieces together on the building facade.

The foundation of this research is to continuously attach the two

component of the facade as one component. The metal component including frames on the window system, spider connection and the

glass. Functionally graded material of glass and metal has been used as the research guide.

On the micro level, we have developed the experiment of metal and

glass fusion realistically. At the very beginning of the research we used glass wax as the representational material of glass. In order to under-

stand the behaviour of these transparent material and metal component. On the experimentation level we have established that the two material has been well merged together and formed a gradient in between the materials.

Later on, throughout the course we have used the actual glass and

metal in order to explore deeper and understand the behaviour and connection between these two materials as a functionally graded material.

CHAPTER 02 PROJECT INTRODUCTION

Curtain Wall System

Frame-Support curtain wall system

Unitized curtain wall system

Frame-support curtain wall system is a kind of glass curtain wall whose frame is bare outside.

It involves assembling by means of interlocking units that are bought from the factory.

Hidden frame curtain wall system

Point-support curtain wall system

It conceals the metal frame in the back of glass, that the metal frame is not seen outside.

It consists of glass panel, point-support device and metallic supporting structure.

Introduction of Curtain Wall System Curtain wall is an outer covering of a building, the classification of curtain walls may depend on different characteristics. In our case, we divided curtain wall systems into four types: point-support curtain wall system, frame-support curtain wall system, unitized curtain wall system and hidden-frame curtain wall system. 24

CHAPTER 02 PROJECT INTRODUCTION

Point-support Curtain Wall System

Problem 1. The inadequacy of structural adhesive.

Problem 3. Different thermal expansion coefficients of metal and glass causing a loose fitting between the different parts of the panel.

Problem 2. The loosening up of the connection of the panel to its supporting steel bracket structure.

Problem 4. Heterogeneous load distribution, but homogeneous glass and aluminium material use.

The Current Problems with Point-Support Curtain Wall System Point-support curtain wall system with typical structure is the object of this study. Currently, the life of curtain wall systems cannot exceed the life of buildings. The problems them have a considerable effect on the building’s life-cycle cost, and a system’s durability must be accurately assessed. 25

CHAPTER 02 PROJECT INTRODUCTION

Functionally Graded Material (FGM) In a Functionally Graded Material (FGM) both the composition and the structure gradually change over the volume, resulting in corresponding changes in the properties of the material. The structural unit of an FGM is referred to as an element or a material ingredient. It is a conceptual unit for constructing an FGM that includes various aspects of its chemical composition, physical state, and geometrical configuration. The term, material ingredient, probably expresses the overall concept best. Material ingredients can resemble biological units such as cells and tissues. For example, bamboo, shell, tooth, and bone all have graded structures consisting of biological material ingredients. FGMs can be composed of various material ingredients inorganic, organic, ceramic, metal, polymer chemical electronic state, ionic state physical Functionally graded materials (FGMs) are materials that comprise a spatial gradation in structure and/or composition, tailored for a specific performance or function. FGMs are not technically a separate class of materials but rather represent an engineering approach to modify the structural and/or chemical arrangement of materials or elements. This approach is most beneficial when a component has diverse and seemingly contradictory property requirements, such as the necessity for high hardness and high toughness in wear-resistant coatings.

The Research of FGM Functionally graded materials (FGMs) are materials that comprise a spatial gradation in structure and/or composition, tailored for a specific performance or function.

CHAPTER 02 PROJECT INTRODUCTION

In the vegetative tissues of plants, a material similar to FGM was found that can smoothly transition from cell wall tissue to the other tissues.

The silica in the agate contains different trace elements, presents different colours, and they are evenly distributed between.

Reference Miyamoto, Y., Kaysser, W.A., Rabin, B.H., Kawasaki, A. and Ford, R.G. eds., 2013. Functionally graded materials: design, processing and applications (Vol. 5). Springer Science & Business Media.

The Research of FGM Functionally graded materials (FGMs) are materials that comprise a spatial gradation in structure and/or composition, tailored for a specific performance or function.

CHAPTER 02 PROJECT INTRODUCTION

Research Aims: • Reject the discrete panel assembly paradigm. • Propose a materially continuous and heterogenous facade system that avoids the use of discrete parts.

CHAPTER 02 PROJECT INTRODUCTION

Structure of Point-Support Curtain Wall System Based on the aims of study, we decided to optimize the structure of point-support curtain wall. On the one hand, from comstruction point of view, analyzing the structure and find out the key component. On the other hand, speaking for material research, separating two basic material which are glass and metal. Study will begin with these two aspects. 30

CHAPTER 02 PROJECT INTRODUCTION

Glass Wax British Wax Product Code 2452 Chemical Type: Mixture Chemical Description: Proprietary blend Hydrocarbon polymers

Low Melt Alloy

Bullseye Frit

Alloys are defined by a metallic bonding character.

Bullseye frit is made from crushed, screened and magnetically cleaned Bullseye compatible sheet glass. Frits are versatile and can be used in kiln-casting, kiln-forming, torch-working and blowing.

Melting Point: 138C-170C Elements: 40%Bismuth 60%Tin

Basic physical and chemical properties: Physical state: Waxy Solid Colour: Transparent Melting point, °C> 110 Pouring point, °C> 130 Flash point, °C> 200 Autoignition point, °C > 300 Relative density 0.95-1.05 Solubility Water: Insoluble Ethanol: Insoluble Ether: Soluble

Glass Wax is specially formulated to give a unique glass effect. It can be heated and hand poured when molten; for best results use silicone rubber or silicone coated moulds.

Iron Powder (Cold Cast Atomized Metal)

Sheet Glass

Atomized iron is very susceptible to rusting if exposed to moisture, care should be taken to keep it dry. Melting Point:1371 - 1483 °C Boiling Point: 2850 - 3150 °C

Glass is a non-crystalline amorphous solid that is often transparent and has widespread practical, technological, and decorative usage in, for example, window panes, tableware, and optoelectronic.

Bronze Powder (Natural Copper) Appearance: Gold coloured powder Melting point/freezing point, °C=900 Decomposition temperature decomposition/melting begins at 1083°C

Research Material Selection At the begining, we use glass wax, low melt alloy and iron powder to make physical model since they are widely accessible, low cost and easy to manufacture. After a varied of experiments, we try to fabricate real glass and metal. Crushed glass and glass piece have their own chararistics so we use them in different way. 31

CHAPTER 02 PROJECT INTRODUCTION

15% Metal + 85% Glass Wax

10% Metal + 90% Glass Wax

25% Metal + 75% Glass Wax

20% Metal + 80% Glass Wax

35% Metal + 65% Glass Wax

30% Metal + 70% Glass Wax

55% Metal + 45% Glass Wax

60% Metal + 40% Glass Wax

85% Metal + 15% Glass Wax

70% Metal + 30% Glass Wax

Material Gradient Examples These examples show different percentage of glass wax and metal mixture. This experiment have two steps, firstly, using glass wax and metal as fabrication materials and melting them. Secondly, mixing glass wax and metal with stirring. Different percentage of materials effect the colour, viscosity, appearance,weight and hardness of results. 32

CHAPTER 02 PROJECT INTRODUCTION

100% Alloy

90% Alloy + 10% Glass Wax

80% Alloy + 20% Glass Wax

70% Alloy + 30% Glass Wax

60% Alloy + 40% Glass Wax

50% Alloy + 50% Glass Wax

40% Alloy + 60% Glass Wax

30% Alloy + 70% Glass Wax

20% Alloy + 80% Glass Wax

10% Alloy + 90% Glass Wax

100% Glass Wax

Material Gradient Examples This example makes the container as a concentric circle, it can be used as a reference model of mixing glass wax and metal in different proportions. It shows a clear colour gradation, some small changes or differences between every grade of material mixture could be defined. 33

CHAPTER 02 PROJECT INTRODUCTION

Glass and Metal Fusion Picture above shows the result of glass and metal fused using casting method. The metal fluid is in blue and dark grey and the glass is in transparent. There are bubbles occur in the glass transparency. The following step is to reduce the amount of bubbles in the glass viscosity and increase the transparency. 34

CHAPTER 02 PROJECT INTRODUCTION

Approach 1. Load analysis

Approach 2. Topological optimization

Approach 3. Real Flow Simulation

Outcome

Design Approach Topological optimization and material simulation are two key methods for this design. The reason why we choose RealFlow is its partical system, it can easily import the materials data, relatively small amount of computation and more suitable for fluid particle simulation. We can predict material behavior by this process. 35

CHAPTER 03

PROJECT DESIGN

CHAPTER 03 PROJECT DESIGN

DESIGN DESCRIPTION Going Against Discrete Construction A curtain wall system responds to the increasing demand for building façades, such as requiring smaller wall occupancy, a lighter structure, flexible accommodation capabilities, advanced lighting channels and more independent building layouts.

This design seeks to combine structural optimisation with function-

ally graded material to create a structural curtain wall system, which

technically simplifies the structural connection of the glass curtain wall

and maximises the performance of the material. One of the highlights in this part is to design the connection of the structural part in fusing it with the glazing component. The design of the branch connection and the glazing are well connected to smoothly join and connect those two component in certain gradient.

This chapter follows a certain design concept, by dividing a curtain wall system into three parts which are glass panel, metallic sup-

porting structure and point-support device, then run topological

optimization and material simulation separately, finally combine these results together to create a final outcome.

Chapter 3.1 Digital Design

3.1.1 Glass panel design

3.2.2 Metallic supporting structure (metallic frame) design 3.3.3 Point-support device (spider) design Chapter 3.2 Fabrication

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Curtain Wall

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Curtain Wall Exploded Axo

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Metal Frame

Spider

Glass

Curtain Wall Connecting Components The schematic diagram of the curtain wall structure clearly shows that the spider is a connection in the curtain wall structure and it is a connection between two materials.

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Spider Connection Detail Spider is a transition zone connecting the metal part and the glass part, bearing the responsibility of connecting two different materials

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GLASS PANEL DESIGN In this part, we have developed the glass panel design. Facade as a

shell of the buildings that is important to protect and shape the building designs itself.

We have used weaver bird and millipede grasshopper that derived

from the result of topology optimization. The Voronoi diagram is simply the tuple of cells. In principle, some of the sites can intersect and

even coincide, but usually they are assumed to be disjoint. In addition, infinitely many sites are allowed in the definition (this setting has ap-

plications in geometry of numbers and crystallography), but again, in many cases only finitely many sites are considered.

In the particular case where the space is a finite-dimensional Euclide-

an space, each site is a point, there are finitely many points and all of them are different, then the Voronoi cells are convex polytopes and they can be represented in a combinatorial way using their vertices,

sides, 2-dimensional faces, etc. The induced combinatorial structure is referred to as the Voronoi diagram. However, in his case the Voronoi

cells are even connected to each other to fuse the connection between two components.

The wider aim of this research is to explore the architectural potential of

additive manufacturing for prefabricating large-scale building components. It investigates the use of additive manufacturing for producing

building components with highly detailed and complex geometry, re-

ducing material use and facilitating the integration of technical infrastructure.

In order to achieve this, the concept of connecting form-work is intro-

duced. The shape is employed to produce a connection form-works for the glass design, regardless of geometric complexity. This approach

explores the synergy between the geometric flexibility of the glass and

the structural capacity. It allows the production of composite components with properties superior to either individual material.

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X=0.000, Y=0.000-0.400

Y=0.000, X=0.000-0.400

Y=0.000-0.400, X=0.000-0.400

Y=0.000-0.400, X=0.000-0.400 Topological Optimization on Glass When wind load, dead load and other loads are applied to a piece of glass, the shape of glass might change. Because loads on every area of glass are not homogeneous, we need to simulate the condition. These images show the results of topological optimization. 46

CHAPTER 03 PROJECT DESIGN

Scan & Solve Verification Scan&Solve can simulate bonded assemblies consisting of solid geometry, and it also supports material selections such as wood, steel and glass. Images show that inhomogeneous load-bearing of a piece of glass. After this step, we can optimize this glass by reducing material. 47

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Form Pattern from Topology Result After the simulation on a piece of glass, some stress lines which are formed by wind load and dead load show on the surface, therefore we can extract them, they explain the pattern of material distribution.

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Glass Design Development Firstly, the stress lines are denseness, we can implify and beautify the pattern. The last image is final outcome of a piece of glass.

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Size of Curtain Wall System According to general curtain wall facade size, the design size of a piece of glass is 350mm (width)* 700mm (height)* 10mm( thickness). The whole facade has four pieces of glass in the horizontal direction, three pieces of glass in the vertical direction, in total, 2100mm (height)*1400mm(width)* 10mm (thickness). 50

CHAPTER 03 PROJECT DESIGN

Loads on Curtain Wall System In this case, we set up wind load and dead load on a facade, once the boundaries of the structure and loads are controllable, the initial load working form can be visualised. Then, we can manually edit this shape for better performance while maintaining the connection principle of the structure. 51

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Facade Pattern Experiment In this process, we select a few points on facade to test the pattern. It cannot complete the topological optimize because points effect each other and the grasshopper did not recognize all the load settings.

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Facade Pattern Outcome This image shows the result of this experiment, load contribution diverges from the centre to the periphery. Preliminary results show that experiment may be in accordance with the theoretical calculation.

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Final Facade Design This image shows that how to select point based on basic load analysis, these point follow a definite pattern of distribution in certain surface. This facade could be part of a building outer cover, comparing with large building facade, this scale could obtain more precision of stress value. 54

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Pattern on Top Part

Pattern on Middle Part

Pattern on Bottom Part

Pattern on the Whole Facade

Topological Optimization Strategy Divide the facade into three parts which are top-part, middle-part and bottom-part, because height is the most important factor which effect the wind load and dead load. 55

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Pattern Development Firstly, combining three topological optimization together, the pattern show like this image. Pattern on bottom part effects by the support on ground, and on top part shows more wind load contribution, as for middle part, spider support is the main reason that form pattern like radiation. 56

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Pattern Development After the first step on last page, the pattern need to be simplified. We choose spider connection area as main focus area, stress lines in these area

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Pattern Development Make all the lines to be continuous curve, and in some way, connecting smoothly.

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Facade Pattern Rendering This image shows the rendering of facade pattern design.

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METALLIC SUPPORTING FRAME DESIGN In the façade structure, every material has its specific qualities and responsibility. In a thermal transfer function, different materials can be used as an insulator or a conductor.

The metal part is an important component in the facade. For this part design, we use the same strategy to develop it based on the real facade structure.

Topology optimimzation is used for discrete structures like trusses and frames and could achieve the optimal designs by finding the most suitable location and geometries.

On the metal body, it bear force in different part. Use those force points as references in topology software and simplify the result in a reasonable way.

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Topology Target

Metal Topology Analysis This is the typical curtain wall structure, chose one part of the metal frame to topology

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Metal Topology Analysis Chose the exact force bearing points of the metal frame and simulate it to get the shape

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Frame 1

Frame 2

Frame 3

Frame 4

Frame 5

Frame 6

Frame 1

Topological Optimization of Metal Use the exact force that the metal bear and use millipede to generate the metal frame.

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Frame 1

Frame 7

Frame 8

Frame 9

Frame 10

Frame 11

Frame 12

Topological Optimization of Metal Use the exact force that the metal bear and use millipede to generate the metal frame.

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POINT-SUPPORT DEVICE DESIGN Spider Design A facade consists of two kinds of areas – an opaque area and a

transparent area. Spandrel column covers include the opaque part

while vision glass or without frame make up the transparent part. The fundamental principle is non-transparent and transparent no matter

what style the facade is, what composition it is, or what kind of specific cladding material is used in a typical facade, glass and metal are two kinds of materials that occupy the majority area of a facade.

Spider is typical connection between this two part. The design process is basic on the original shape of the spider and find out a more reasonable way to develop it.

The technique we have used for the development is topology optimization. The main purpose of topology optimisation is to find out the best performance for a structure under various conditions likes a given amount of material.

In this part, there are three generation process. First, use millipede to

topology the orignal sipder. second, based on the topology result, use shortest walk and L-system to inspire. Finally, combine all the result and design our spider outcome.

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Topological Optimization Result 1

Simulation Result 1

Topological Optimization Result 2

Simulation Result 2

Topological Optimization Result 3

Simulation Result 3

Topological Optimization Result 4

Simulation Result 4

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Basic Topology Optimization The above process is the topology analysis of the single point of the cantilever beam, and the morphology of the beam is simplified through mechanical analysis. In this series of simulation and optimization, metal material and the glass wax material are mixed by the force of vortex. 68

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Topological Optimization Result 1

Simulation Result 1

Topological Optimization Result 2

Simulation Result 2

Topological Optimization Result 3

Simulation Result 3

Topological Optimization Result 4

Simulation Result 4

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

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Topological Optimization Result 1

Simulation Result 1

Topological Optimization Result 2

Simulation Result 2

Topological Optimization Result 3

Simulation Result 3

Topological Optimization Result 4

Simulation Result 4

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

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Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Basic Topology Optimization The above process is the topology analysis of the point-support device (spider), and the morphology of the spider is simplified through mechanical analysis. In this series of simulation and optimization, metal material and the glass wax material are mixed by the force of vortex. 71

CHAPTER 03 PROJECT DESIGN

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

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Simulation Process (Millipede) Pictures above shown the shape development based on the topology optimization result using Milipede plug-in for grasshopper. To create a lighter, stronger and more efficient result, we combined the result of these topology optimisation to refine the geometry shapes in parallel by running multiple optimizations and loads when simulating. 73

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Topological Optimization Development From the result of Topology, we’ve blend the both topology optimization and traditional design method to create more complexity and geometry form.

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Simulation Process (Shortest Walk) By using different method to form a branch we managed to study some ways and method to branches out the connection. In this part we used a plug-in in grasshopper called shortest walk

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Simulation Process To generate more complex geometry and design, by blending the shortest walk method and voronoi resulting designs are of more complexity and connection between them. This idea is parallel with the idea of fusing the facade and sturture together to merge them together in one component 76

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Branching Structure The branches has been developed more into a structure component. To make it more stronger and structured form, we’ve developed the design with some thickness to the branches.

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Branching Variations Branching structures are based on geometric systems that expand through bifurcation without returning to closed loops. In this sense, branching structures resemble the structure of trees that branch continually outward. The structural system adopted here is a tree-branch. The structure is supported on rows of tree-like columns running the length of the entire building. As the structure branches into finer structural members as it approaches the ceiling. The structure part is the integration of tree-like structure. The actual branching surface is divided into sections; each supported by a “steel tree” with passes the loads down through the branches to be collected in the tree trunk. Branching structures exhibit a particularly close relationship between the course of the forces and their shape, both in their overall appearance and in the nature of the structure itself. We started to emulate different variations of branching structure systems. Beginning first with a single level of branching and then moving to a second and a third level to understand how the systems are formed. In this part we also developed the branching systems through different method such as using Real Flow technique, Shortest Walk and etc.

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the Branches in the Facade

the Original Lines for Branches

the Development Lines for Branches

Extract the Central Line of the Branches In order to develop the connection part, we extract the centre line to analysis

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Extract Lines From the Branches

Simplified Lines From the Extract Lines

Extract the Central Line of the Branches In order to develop the connection part, we extract the centre line to analysis

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L-systems For centuries, architects have been inspired by natural forms and geometries. Their designs have been influenced by natural structures, proportions, colors, patterns and textures. In 1968, the biologist Aristid Lindenmayer proposed a stringrewriting algorithm which can model plants and their growth processes. Since then, Lindenmayer Systems or L-systems have evolved and found many practical applications in the computer visualization area, such as generation of fractal diagram, realistic modeling and high quality visualization of organic forms. More recently, remarkable advances have been made in architecture in the field of modeling and visualization. Specifically, the integration of scripting languages into CAD applications enables direct visualization of objects generated using algorithmic processes. Therefore, L-system is ready to be a new tool for architects, and in the meantime architecture gain more opportunities to be designed with complex, organic or bionic ways by using parametric tools such as Rhino with Grasshopper. However, how can the L-system apply to architectural design process through parametric tools? How to make L-system adapt to an architectural site? Based on the parametric environments and biology, L-system will propose an experiment of organic structure which would be constructed without traditional, latticed framework, enabling the structure to create by means of natural creature or organic elements. It then could be optimized through the computer program with not only inspiring from the natural system that has evolved efficiently, but also adjusting to several environmental factors such as solar, wind, acoustics or temperature.

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2D Branches Simulation F=F[+F]F[-F]F Angle: 45°

2D Branches Simulation F=F[+F]F[-F][F] Angle: 45°

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2D Branches Simulation X=F[+X]F[-X]+X F=FF Angle: 32°

2D Branches Simulation X=F[+X][-X]FX F=FF Angle: 32° 87

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3D Branches Simulation Axiom: FFA Rules: A=!""[B]////[B]////B B=&FFFAJ Angle: 32° 88

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3D Branches Simulation Axiom: FFFA Rules: A=!""[B]////[B]////B Angle: 32° 89

B=&FFFAJ

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One Point

Three Points

Two Points

Four Points

Process One Generate the connected lines between the points and the flat

Process Two Follow the lines getting the broken lines through the path

Process Three Follow the lines getting the curve through the path

Process Four Follow the curves generate the branches

Points Generation Process Generate the branches from one point and two points to many points which are in a flat surface then form the structure

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Process One

Process Two

Process Three

Process Four

Top View Rendering

Top View of Four Points Generation Process Generate the branches from one point to many points which are in a flat surface then form the structure, those pictures showing the top view of the process

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One Point Generate Branch to a Twist Surface Generate the branches from one point to many points which are located a twist surface and form the structure, those pictures showing the front view of the process

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Branches Generation This is the rendering of generate the branches from one points to many points

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Sub-structure of the Branches By using grasshopper to add more detail to the structrue.

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Basic Components We use a dodecahedron to generate the basic path for branches.

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Generation Process After done the topology optimization result, we use other technique to explore more possibilities. That is the result from shortest walk with different numbers of support points.

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Basic Components We use a dodecahedron to generate the basic path for branches.

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Glass

Frame

Metal Frame

Glass

Frame

Metal Frame

Glass

Frame

Metal Frame

Glass

Frame

Metal Frame

Glass

Frame

Metal Frame

Glass

Frame

Metal Frame

Glass

Frame

Metal Frame

Glass

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Metal Frame

Glass

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Metal Frame

Topological Optimization Analysis Between the glass and metal frame, use topology technique to generate the connection. Different points can lend to different result.

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Metal Frame

Glass

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Metal Frame

Glass

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Metal Frame

Glass

Frame

Metal Frame

Glass

Frame

Metal Frame

Glass

Frame

Metal Frame

Topological Optimization Analysis Between the glass and metal frame, use topology technique to generate the connection. Different points can lend to different result.

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Glass

Frame

Glass

Frame

Glass

Frame

Glass

Frame

Glass

Frame

Glass

Frame

Glass

Frame

Glass

Frame

Topological Optimization Analysis Between the glass and metal frame, use topology technique to generate the connection. Different points can lend to different result.

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Frame

Glass

Frame

Final Outcome of Spider The spider will fuse glass and metal together and showing the gradient

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Force Points

Front View of Spider Force Points Location Chose the exact force bearing points of the metal frame and simulate it to get the shape

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350mm

700mm

2800mm

700mm

1400mm

Glass Surface Topology Analysis 01 Chose one part of the whole facade to do the topology optimization

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Spider Location

Radiation Range

Stress Points

Glass Surface Topology Analysis 01 One part of glass surface with spider location

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Frame 1

Frame 2

Frame 3

Frame 4

Frame 5

Frame 6

Frame 7

Frame 8

Frame 9

Spider Topology Analysis 01 Choose one force point in the metal part and two force points in the metal partto topology and generate the conection between them.

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Frame 1

Frame 2

Frame 3

Frame 4

Frame 5

Frame 6

Frame 7

Frame 8

Frame 9

Spider Topology Analysis 02 Choose one force point in the metal part and three force points in the metal part to topology and generate the conection between them.

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Frame 1

Frame 2

Frame 3

Frame 4

Frame 5

Frame 6

Frame 7

Frame 8

Frame 9

F F

Spider Topology Analysis 03 Choose two force points in the metal part and four force points in the metal part to topology and generate the conection between them.

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Load Area 1

Load Area 2

Load Area 3

Spider Development Last page we get a basic spider shape by connecting point to point and optimizing the solid geometry by topology analysis, this s step we will choose specific points from previous glass panel design and metallic supporting structure design, then, running topological optimization for the first time. 108

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Step 1. Choose certain points on glass panel. These points should be located in the load-focusing area and can be connected by lines.

Step 2. Build a topological model which parameter function can reflect design intention and endow attributes, also the model is easy to revising.

Step 3. Optimizing this model in Millipede program, according to physics, this result consists of some traces of materials on carriers under the function of forces.

Spider Development A complete process can be created by combing these three steps into a sub-process, and reused again later in the more complex design, continuing this process can get the shape of spider. Though each of these steps is required, which points can be selected, how many points is right and how many times the steps is performed varies with each topological optimization. 109

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New Design Facade One part of the whole facade final result

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New Design Facade One part of the whole facade final result

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700 mm 700 mm 700 mm

350 mm

Glass Surface Topology Development This the development of the glass surface topology analysis

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Glass Surface Topology Development This the development of the glass surface topology analysis

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New Design Facade Glass pattern

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Final Outcome of Spider The spider will fuse glass and metal together and showing the gradient

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Particle Generation This part is to do the research on how to generate the gradient in dig-

ital way. We use series of technology means (Grasshopper, Rhino, Real Flow, Maya, etc.) to simulate.

The proposal of this is to find the micro details of the model and try to

find out some interesting results. In other word, this part is a research

process. After the simulation, the interest results are really useful and helpful, and that is where inspire our project.

In the first term, our project gets the structure by topology the con-

nection part in the curtain wall. That structure contains two particle

system, in other word, it contains two materials. In the first grope, we set a series of points from the surface of the model, and use that

points to from an organized wet on the surface of the model. In other word, we add more details in the model.

In the second grope process, we try to use one particle system to do the simulation. But actually, there are two particle systems in our project model. So in the third grope process, we try to add another particle system into the simulation, and find out some interesting results.

In order to create the gradient for the model, this part we did series of test to create the gradient. We are thinking that if we create a gradient holes for the surface, and filled the holes by the different material that means we create a multi-materials in some way.

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First Step Filling the surface of the object with the points. That means extract the information of the surface into those points. After that, those points can be use as reference points to next points.

Second Step As we already have the reference points, we can get curves by those reference points. Since all the points are random and without organized, we can set curves in weaverbird like a network.

Third Step When we already got the network, we would try to create different size of holes in order to create the gradient.

First Research Process--Surface Arrange In the first grope, we set a series of points from the surface of the model, and use that points to from a organized wet on the surface of the model. In other word, we add more details in the model.

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Present Step Got the boundary of the object then layout the boundary of the object in the Real Flow software to fill it inside space with particles.

First Step Filling the object in the Real Flow software. In the Real Flow, set the particles shows in a random way but within the boundary of the object. That is a kind of reference points which give an opportunity to continue doing the micro details.

Second Research Process: One Particle System That we use Real Flow to fill particles into the topology model and using grasshopper to give it new life. Actually, before we did this, we don’t know what can we get, it is just a kind of grope process and maybe it can spire our project. For the first grope, we only use one particle system. 120

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Second Step As we already have the reference points, we can get curves by those reference points. Since all the points are random and without organized, so by triangulate them, we can get a series of curves which form the triangle.

Third Step After we get the triangulation, we can develop the micro details by exoskeleton them. Actually, since there too many curves to calculate, all those curves needed be optimized. After that, we got an interesting result.

Second Research Process: One Particle System That we use real Flow to fill particles into the topology model and using grasshopper to give it new life. Actually, before we did this, we don’t know what can we get, it is just a kind of grope process and maybe it can inspire our project. For the first grope, we only use one particle system. 121

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Frame 10

Frame 50

Frame 90

Frame 130

Frame 170

Frame 210

Frame 250

Frame 290

Frame 330

Third Research Process: Particle System Running That structure contains two particle system, actually, it contains two materials. That we use Soft Image to let the particles run along the surface of the model.

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Second Step Attach the colours to the skeleton along to the materials information.

Fourth Research Process: Two Particle Systems But actually, there are two particle systems in our project model. So in the third grope process, we try to add another particle system into the simulation, and find out some interesting results.

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Third Step Mixed those different materials skeleton model.

Fourth Step Then we need adjust it to make it suit all the property.

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First Step Filling the object in the Real Flow software. In the Real flow, set the particles shows in a random way but within the boundary of the object. That is a kind of reference points which give an opportunity to continue doing the micro details.

Second Step As we already have the reference points of the particle system, we can build the mesh and export the mesh as object. Then import the object file of mesh into the rhino.

Third Step Combing the mesh and the RGB colour vertex together. Thus we got the colour mesh with gradient.

Fourth Step Getting the model with multi material, red part stand for glass while yellow part stand for metal.

Real Flow Particle System That structure contains two particle system, actually, it contains two material. That we use Real Flow to fill particles into the topology model and using grasshopper to give it new life. We use the python to export the RGB vertex colour and attach it in the mesh to form the gradient. 134

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Fourth Step Two kinds of material come from two side of the model and mixed together in the middle of the model

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Noise Analysis By using the noise analysis tools, the model shows like a hairy one with many micro details.

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Reference: https://www.archdaily.com/610939/synthesis-design-architecture-utilizes-gradient-3-d-printing-in-durotaxis-chair/

Reference The architects bounced among multiple software programs including Rhino, Grasshopper, Weaverbird, Z-Brush, and Maya to craft a form that operates in two positions: upright, as a traditional rocking chair, and horizontally, as a lounger.

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Second Research Process: Colour Attachment In the first term, our project gets the structure by topology the connection part in the curtain wall. That structure contains two particle system, actually, it contains two material. Thus means we can use different colours to show the gradient in the model.

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Reference: https://www.flickr.com/photos/optical_illusion/3174020645/

Gradient Research How the wall turns from one solid looking piece to multiple wavy pieces reflecting, shows the transition of all the pieces coming together to form a cool piece of architecture. On the lower level the colour yellow is used, which gradually changes to green towards the top of the building. The particular shade of green that was chosen reflects the public garden on the corner of the Oostersingel and the Antonius Deusinglaan opposite the building. 142

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Gradient Size Showing the Change

Real Flow Particle system In the first term, our project gets the structure by topology the connection part in the curtain wall. We use the python to export the RGB vertex colour and attach it in the mesh to form the gradient.

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Reference: https://www.flickr.com/photos/flaneur/504674697

Gradient Research When I set off to be an artist, I would avoid the arbitrary, esteem the orders of God in Nature, make things that were beautiful, try to make things that appeared to have no author, things you thought you had seen before; entwined with mathematics, geometry, topography, spinning, interlocking. Reference. In San Francisco. Charles O. Perry sculpted this piece, titled “ Eclipse ”.

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Skeleton Gradient

Gradient Research We use the python to export the RGB vertex colour and attach it in the mesh to form the gradient.

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Step one

Step two

Step three

Step four

Step five

Gradient Research In order to create the gradient skeleton, the first step is to create a box filled with the populate points. After the populate points, we should take off some pints by logic since we want the gradient. After the gradient points which generate in grasshopper, the lines would used to connect the points for the nearest five points. After the populate points, we should take off some pints by logic since we want the gradient. 146

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Gradient Research Attach the colour to the gradient skeleton and the network model.

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Sub-structure from the Simulation Use the net to generate more detail for this shape and get a more interest result

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Sub-structure from the Simulation Use the net to generate more detail for this shape and get a more interest result

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Gradient Circle That structure contains two particle system, actually, it contains two material. That we use Real Flow to fill particles into the topology model and using grasshopper to give it new life. We use the python to export the RGB vertex colour and attach it in the mesh to form the gradient. 152

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Gradient- metal fusing glass-Spider Using Real Flow to fusing two kind of material

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The Digital Gradient of Glass and Metal Fusion This image show that the digital gradient of metal and glass fusion in a spider.

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The Digital Gradient of Glass and Metal Fusion This two images show that the digital gradient of metal and glass fusion in complete structure view.

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FINAL OUTCOME This part is all the facade design outcome. Explore collaborative work of topology optimisation and FGM material-based design, achieving not only the beauty of building appearance but also structure

reasonable façade. After getting the result for spider, metal frame, and glass separately, connect them all together can get our facade design outcome.

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Facade Design Outcome 01 Branches has been developed into a structured form. This outcome based on the first spider result.

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Facade Design Outcome 01 The branches has been developed more into a structure component. To make it more stronger and structured form, we have developed the design with some thickness to the branches.

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Facade Design Outcome 01 This is the top view of the first generated result for the facade. The scale of it is 400mm*400mm.

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Facade Design Outcome 02 Based on the metal development and the second design for spider, we get the outcome for one piece of facade. This design need to be developed more cause the topology optimization result need be improved.

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Facade Design Outcome 02 The metal frame is dis-symmetry in the outcome.

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Facade Design Outcome 02 The glass part showing the beautiful pattern based on the topology optimization result.

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Facade Design Outcome 03 Connected the third result design branches with the result of topology and meal frame topology, we get a façade which is more reasonable and reliable. The new façade is not just has a markable shape, but it also would be build by multi-material. That many problems can be solved like the water leak. The branches part would has gradient inside as well as the façade itself. 167

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Facade Design Outcome 03 On the glass pattern, the metal frame would fuse with the glass.

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Facade Design Outcome 03 The design for connected part (spider) is the most important component in facade, in this generation, glass and metal are connected with the gradient inside.

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External Glass Pattern for Outcome 03 From the outside of the façade, the glass pattern part would showing the glazing and wave.

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External Glass Pattern for Outcome 03 The glass parttern can showing the different sideview from inside room.

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Metal Pattern for Outcome 03 From the inside door, the metal part would connected to the bean or column.

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The Scale of Facade Outcome 03 This image showing the façade install in the building and the view from the interior room. Actually, the whole connected façade don’t need to open for air since it can get fresh air from the gaps.

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The Scale of Facade of Outcome 03 Apply the facade to the building, the light showing beautiful pattern according to the pattern of glass and metal

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Facade Design Outcome 04 Connected the fourth result design branches with the result of topology and meal frame topology, we get the final façade design outcome. The new façade is not just has a markable shape, but it also would be build by multi-material. That many problems can be solved like the water leak. The branches part would has gradient inside as well as the façade itself. 179

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Metal Fusing Glass

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Metal Fusing Glass

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The Proposal of Facade Outcome 04 When apply the topology optimizatin to the whole facade, it would showing a more beautiful and reasonable design result with gradient inside the parttern.

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20 mm

Without Spider

Entire Spider

Half Spider

The Scale of Facade of Outcome 04 the side view of the whole facade showing there are different size of spider..

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The Metal Frame of Facade Outcome 04 The metal frame connected with spider and glass smoothly.

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The Scale of Facade of Outcome 04 The glass part would fuse with the metal frame with internal gradient.

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The Scale of Facade of Outcome 04 The glass part would fusing together with the metal frame with internal gradient

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Metal Frame

Spider Three Floor Glass Surface

Second Floor

First Floor

Ground Floor

Basement

Section of the Facade Design Outcome 04 The façade contains three parts, the metal frame would connect with the spider as the same time, it would connect with the floors or the columns.

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Reference: cd.ln.vox-cdn.com

Maison de Verre Maison de Verre is located in Pairs, France, built in 1932, the house uses various industrial and mechanical fixtures juxtaposed with a traditional style of home furnishings all under the transparency and lightness of the façade.

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Reference: http://handhome.net/maison-de-verre/

The Reason of choosing the Building as Reference This façade structure has divided glass and metal frame, which is very close to our design intent. We use the facade structure of this building as a reference, using topology optimization and functional graded materials to transform the connection between glass and metal. 193

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FABRICATION PROCESS Optimizing the Existing Technique In this part of the project, the fabrication development of casting and slumping method in producing the multi-material of glass and metal model projecting the foundation of this research in the cluster.

In the very beginning of the fabrication, we used glass wax and metal as the representation of glass and metal powder as the metal com-

ponent. In the beginning of this phase it is explained on the material studies of the actual glass with different types of metal.

Material studies of these two component has been developed using

various moulding and casting method throughout the research. The first phase of this experiment was experimenting on the moulding method to firing the facade design and skins.

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DIGRAM TITLE-SEGEO UI-9/LIGHT DESCRIPTION-SEGEO UI-8/LIGHT DESCRIPTION-SEGEO UI-8/LIGHT DESCRIPTION-SEGEO UI-8/LIGHT DESCRIPTION-SEGEO UI-8/LIGHT DESCRIPTION-SEGEO UI-8/LIGHT DESCRIPTION-SEGEO UI-8/LIGHT DESCRIPTION-SEGEO UI-8/LIGHT DESCRIPTION-SEGEO UI-8/LIGHT DESCRIPTION-SEGEO UI-8/LIGHT DESCRIPTION-SEGEO UI-8/LIGHT 204

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INITIAL MATERIAL STUDIES Representational Model Using Glass Wax and Metal as the Initial studies Throughout the research, a series of multi-material studies has been

done to understand multi-material in a micro level. At the beginning of our research we have used Glass wax as a representation of glass and metal powder to merge them together and formed a gradient

in between. The research developed and justify a certain character of the multi-material as in FGM concept.

The research started with the simulation of these two liquid using a

software (real flow). This is to understand and predict the two material together in the real life. A series of fluid simulation studies has been done then converted into the physical model. The development of

the process in converting the multi-material into a physical model is

the biggest challenge that requires a certain technical skill and knowledge on making.

Furthermore, in this phase of material studies, led the research to

explore more on the actual glass and metal studies later in the year.

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Model making process 2

Model making process 1

Experiment process 2 on Glass Wax and Metal Step one, put the ice cubes in the bowl, then pour the liquid glass wax into the bowl. The ice cubes would melt after that, and left the shape which shows they existence. Step two, the bowl would be covered by Tin foil which help the model won't stick on the bowl. after the model making process, the tin foil would be tear out only left the model. 206

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Model making process 1

Model making process 2

Experiment process 2 on Glass Wax and Metal Step one, put the ice cubes in the bowl, then pour the liquid glass wax into the bowl. The ice cubes would melt after that, and left the shape which shows they existence. Step two, pour glass wax inside the bowl waiting it become solid. Step three, pour liquid metal on the glass wax and form the model. 207

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Multi-material Facade Development In this part of material studies, we started of by developing the fusing technique between the two components of the facade developed a method to fuse them together.

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Multi-material Facade Development The technique applied was by printing the branches with PLA filament, then made the facade mould out of clay, then pour metal and glass wax.

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3D Printing Moulding Pictures above shows the PLA mould that has been printed to use it as a mould. Rubber mould liquid then been poured to get a solid shape of the mould.

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3D Printing Moulding After the rubber mould process, plaster and silica been poured onto the wax mould before the firing takes place. Pictures above show the result of casting this complex shape.

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APPENDIX

Ice Cube Size: 100mm*100mm

The detail of the glass wax model

Ice Cube Size: 200mm*200mm

The detail of the glass wax model

Ice Cube Size: 500mm*500mm

The detail of the glass wax model

Experiment process 3 on Glass Wax and Metal Use the ice cube to shape the inside space of the model, and use different scale of cube to do the experiment

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3D Printing Model of Topological Optimization Result Stereo-lithography (SLA or SLS; also known as stereolithography apparatus, optical fabrication, photo-solidification, or resin printing) is a form of 3D printing technology used for creating models, prototypes, patterns, and production of parts in a layer by layer fashion using photo polymerization, a process by which light causes chains of molecules to link, forming polymers. 215

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MATERIAL STUDIES The Understand of Multi-Material Fluidity This part of the research introduces the fundamental topics related to Fluid Simulations and Multi-material. Firstly fluid simulations imple-

mentation in architecture and the terminology in hierarchical scales

are described. Secondly, the anatomy of the fabrication of multi-material, gradient formation and the differences of the method of producing.

Furthermore the consequences of digital and traditional fabrication

are described in relation to the results of fluid simulations. The process of glass and fabrication method and their functionally grade materials (FGMs) been refined to describe the strength of the structure produc-

tions. The research has open the door to the possibilities of FGM both digital and traditional fabrication techniques is in context of creating a better product of Multi-Material in architectural design.

The making process too up the duration of at least a week to produce some glass casting materials. This is including the mould making process, cleaning the mould and firing period. The study of fluidity and

the understanding of it in a different level (Micro level) has been one of the main factors to achieve a proper functionally graded material product.

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Glass and Metal Fusion Picture above shows the result of glass and metal fused using casting method. Metal fluid is in blue colour and dark grey and the glass is in transparent. There are bubbles occur in the glass transparency. The following step is to reduce the amount of bubbles in the glass viscosity and increase the transparency. 218

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Glass and Metal Gradient The Picture above shows the gradient formed by glass and metal when it fused together with a certain period of time. The two fluids ,merged together in one same firing schedule. This is due to these two materials have an identical melting point

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Glass and Metal Fusion Experimentation Picture above shows the result of glass and metal fused with the same casting method. With the same temperature and of the highest and lowest melting point. The types of metal that has been used was brass in this particular experiment.

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Types of Fusing Glass and Metal Different types of metal and glass is one of the main factors in making sure that these two material merge together and fused nicely. In this particular research is to choose the type of metal that has quite and identical character and behaviour in order to fuse them together perfectly on a micro level. 221

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Glass and Metal Fusion The following diagram describing the result of glass and metal fused with the same casting method but a different type of glass, which is random crashed glass. With the same temperature and of the highest and lowest melting point. The types of metal that has been used was brass in this particular experiment. The result proves that,only fused glass is compatible to fuse with metal. 222

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Types of metal: Brass Filler,Graded:Fine,Melting point: 700 °C, Crash unfusing glass , Melting point: 1000 °C

Types of metal: Brass Filler,Graded:Fine,Melting point: 700 °C, Bullseye Frits-Clear, Graded: Fine , Melting point: 1000 °C

Types of metal:Brass Filler,Graded:Fine,Melting point: 700 °C, Crash unfusing glass , Melting point: 1000 °C

Gradient of Fusion Glass and Metals The above pictures show a broad overview of how the glasses act in same temperature ranges. All of the glasses do not behave identically following a certain rules and ranges. Some very slight fusing with glass and some parts of the glass has a gap in between and did not form a gradient between them. 223

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Glass and Metal Fusion Experimentation Picture above explains the glass and metal fusion on a micro level. These two materials fired in a same melting temperature and firing schedule including kneading time and cooling off period. This part of the research is very important on the understanding of the behaviour of these two materials on a micro level. 224

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Types of metal: Iron Filler,Graded:Coarse,Melting point: 500 °C, Bullseye Frits-Clear, Graded: Medium , Melting point: 1000 °C

Types of metal: Iron Filler,Graded:Fine,Melting point: 700 °C, Bullseye Frits-Clear, Graded: Coarse , Melting point: 1000 °C

Types of metal: Iron Filler,Graded:Fine,Melting point: 700 °C, Bullseye Frits-Clear, Graded: Fine , Melting point: 1000 °C

Types of metal: Brass Metal Filler,Graded:Fine,Melting point: 1000 °C, Bullseye Frits-Clear, Graded: Medium , Melting point: 1000 °C

Types of metal: Iron Filler,Graded:Fine,Melting point: 700 °C, Bullseye Frits-Clear, Graded: Fine , Melting point: 1000 °C

Types of metal: Brass Metal Filler,Graded:Fine,Melting point: 1000 °C, Bullseye Frits-Clear, Graded: Medium , Melting point: 1000 °C

Types of metal: Iron Filler,Graded:Fine,Melting point: 700 °C, Bullseye Frits-Clear, Graded: Fine , Melting point: 1000 °C

Glass and Metal Fusion The above pictures show a broad overview of how the glasses act in same temperature ranges. All of the glasses do not behave identically following a certain rules and ranges. Some very slight fusing with glass and some parts of the glass has a gap in between and did not form a gradient between them. 225

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Glass and Metal Fusion Picture above shows a glass casting result on a 3D shape, involving mould and casting method. The process of moulding this particular shape involved few stages of moulding, which is wax mould followed by the plaster and silica mould which will be explained later in this chapter. 226

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Glass and metal casting, the shape has been created using CNC technology.

Multi-Material of Glass and metal has been cast using bullseye frits at a temperature of 820 Celsius.

A mixed of glass and metal model by using rubber mould as the mould making method.

Experimentation of mould making using wax being heated in the oven in order to get the exact shape for glass casting

Mould Making Technique Pictures above show the glass and metal fusion results from casting method using a different mould making technique.

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CASTING TECHNIQUE Glass fabrication using kiln-casting technique Glass casting is the process in which glass objects are cast by directing molten glass into a mould where it solidifies. The technique has been used since the Egyptian period. Modern cast glass is formed by a

variety of processes such as kiln casting, or casting into sand, graphite or metal moulds.

The most important criteria and rules in making sure that glass casting turn out perfectly is the firing schedule involving the top temperature,

holding temperature and annealing process. Furthermore, the cooling process also one of the important part in the firing schedule.

The first stage of casting is creating the mould by using plaster and silica in a powder based mixed with a decent amount of water to bond

them together. In order to fabricate the glass pattern from the topology optimization result. The glass pattern has been created and milling using the CNC technology on a Styrofoam then when it is ready the plaster and silica mould being poured on the foam itself.

This process was really important in our research in order to understand the glass casting process on a big scale level. In this chapter,

the whole process will has been documented to achieve the big scale fabrication.

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CNC Process on 600x1200mm Styrofoam Board The pictures above described the pattern that has been created using the CNC technology. Firstly the design has been generated using the topology optimization technique then by setting the tool path of CNC for the milling process to take place.

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CNC on a 100mm Styrofoam Board Picture above shows the glass pattern on the Styrofoam from the topology optimization result in order to create the glass mould out plaster and silica based. The Styrofoam glass pattern then has been used to create the glass out of frits.

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Mould Making Process Picture above shows the process of moving the about 100kg mould made of Plaster and silica being transferred from the workshop to the ground floor of The Bartlett building before it can be transferred to the glass warehouse.

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Mould Making Process of 600x1200mm Glass Facade Pictures above show the process of a glass facade with the size of 600x1200. As shown in the pictures, making a big scale glass needs a lot of man power. Starting from mixing the plaster and silica to transferring the mould to the big glass kiln.

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Firing Glass with Kiln-casting Method Picture above shows the glass frits after being fired in the kiln that stays in the plaster and silica mould. As shown in the picture the frits turns into clear transparent state of glass and increased the transparency quality onto this piece of glass.

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Firing Glass with Kiln-casting Method Picture above shows the glass pattern after the firing took place.

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Glazing Scales This picture describes the scale of the glass that has been produced by a casting method using crystal clear frits with coarse graded size. The size of the glass is 600 x 1200mm.

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Facade Glazing Process The first picture shows a vacuum forming acrylic to project how the actual glass will look like, by using a Styrofoam to get the shape of the glazing design. The thickness of the facade is 50mm thick.

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SLUMPING TECHNIQUE Optimizing The Existing Technique Slumping glass is a highly technical operation that is subject to many variations, both controlled and uncontrolled. When an item is being

slumped in a kiln, the mould over which it is being formed (which can be made of either ceramic, sand or metal) must be coated with a re-

lease agent that will stop the molten glass from sticking to the mould. Such release agents, a typical one being boron nitride, give off toxic fumes when they are first heated and must be used in a ventilated area.

The glass is cut to the shape of the mould (but slightly larger to allow for shrinkage) and placed on top of it, before the kiln is heated.

The stages of the firing can be varied but typically start to climb at

quite a rapid rate until the heat places the glass in an “orange state” i.e., flexible. At that point, gravity will allow the glass to slump into

the old and the temperature is held at a constant for a period that is known as the “soak”. Following this stage, the kiln is allowed to cool slowly so that the slumped glass can anneal and be removed from

the kiln. If two differing colours of glass are used in a single piece of

work, the same CoE (Coefficient of thermal Expansion) glass must be used, or the finished piece will suffer from fractures as the glass will

shrink at differing rates and allow tension to build up to the point of destruction.

To compensate for this, many glass manufacturers subscribe to make glass to the same CoE. Examples include Spectrum glass system 96

or uroborus 96 series, and the use of this glass will allow the cooling to remain uniform and ensure that no tension builds up as the work cools.

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Optimizing the Glazing Thickness The above picture shows the thickness of the glass that has been optimizing using the millipede software then being transferred into triple sheets of glass with 9mm thickness.

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Multi-Material glass and metal using slumping method with the highest temperature of 720 Celsius. (3 Layers)

Multi-Material glass and metal using slumping method with the highest temperature of 720 Celsius has been slumped with (two layers)

Glass test that has been slumped to form the shape from the mould . The highest temperature is 720 Celsius. (2 Layers)

Multi-Material glass that has been slumped in the kiln with the highest temperature of 820 Celsius. ( 2 layers of 3mm glass sheet)

Behaviour of glass when Heated The above pictures show different results of slumping with different temperature ranging from 720-820 Celsius firing. The result explained how firing schedule plays an important rule in making sure that the slumping technique is a success.

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The Unique Nature of Glass The above diagram shows a broad overview of how the glasses act in different temperature ranges. All of the glasses do not behave identically following a certain rules and ranges. Some very slight variations can occur, depending on the viscosity of the individual glass. Furthermore,the specific kiln set-up , and firing cycle used will have a direct impact at any given rules. 242

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The above diagram shows a broad overview of how the glasses act in different temperature ranges. All of the glasses do not behave identically following a certain rules and ranges. Some very slight variations can occur, depending on the viscosity of the individual glass. Furthermore,the specific kiln set-up , and firing cycle used will have a direct impact at any given rules. 243

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Triple Layer of 2mm Glass The picture above shows the result of triple layer of glass that has been slumped into the kiln with the mixed of brass filler and copper at a temperature 720 Celsius. The glass formed a nice slumping following the mould shape.

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Idealized Firing Graph Previously fired glass and whether it was a tack fuse or a full fuse; These factors and others will determine the schedule that has been used to fire your glass pieces. Each factor is an important and critical part of your firing schedule.

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Optimizing the glass thickness By modifying the existing slumping technique, The idea of optimizing the facade glazing has been one of the factor in achieving the best design-slumping projects will usually require relatively low temperatures and longer hold times in the kiln than many other types of kiln-forming projects. The idea is to allow the glass to soften, then gently sink, or slump, into the mould. 246

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Slumping Fabrication Method The temperature and firing schedule you use will be determined by the shape of the project and specific materials that we are using. The mould making and layering technique has been one of the main factors for this.

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Slumping Mould Making Mould making is important and one of the main technical criteria in making sure that the firing of a glass is a success. The picture above shows the mould pattern that has been create using a formation of pattern on Styrofoam using CNC technology

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Slumping Mould Making The above diagram shows a broad overview of how the glasses act in different temperature ranges. All of the glasses do not behave identically following a certain rules and ranges. Some very slight variations can occur, depending on the viscosity of the individual glass. Furthermore,the specific kiln set-up , and firing cycle used will have a direct impact at any given rules. 249

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Clear Transparent Slumped Glass The above diagram shows a broad overview of how the glasses act in different temperature ranges. All of the glasses do not behave identically following a certain rules and ranges. Some very slight variations can occur, depending on the viscosity of the individual glass. Furthermore,the specific kiln set-up , and firing cycle used will have a direct impact at any given rules. 250

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Slumping Glass Pattern Formed The picture shows the thickness of the glass after being slumped into the kiln. The two layers of glass has been merged together and formed following the mould pattern.

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Slumping Result This picture shows the slumping results of a pattern that has been set up using CNC technology and a mixed of handmade plaster and silica mould.

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Slumping Result This picture shows the slumping results of a pattern that has been set up using CNC technology and a mixed of handmade plaster and silica mould. The picture shows in details of the gradient formed within the glass layers.

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Multi-Material Slumping Technique Mixing Metal and Glass Using Slumping Technique Throughout the experiment, the glass slumping technique dependent by various technical aspect in the slumping technique foundation. There are some major factor that needs to be taken into account.

Firstly, the firing graph and schedule. In this part of the research will differentiate the outcome of glass with different firing graph. The

picture here shows a fusion result of glass and metal at the highest temperature of 820 Celsius and a longer holding time.

The major challenge in the slumping process is to fire and fuse the

glass and metal at the right schedule. Throughout the process the se-

ries of experimentation has be done with different number of layers of glass. The best result that has been gathered was by using triple layer of glass slumped into a 30mm plaster and silica mould.

The result shows that the firing schedule at the top temperature and the holding temperature needs suit the types of glass. The sheets of

glass that we used was from bullseye with the thickness of 3mm each and has been layered triple.

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Slumping Glass Result On A Mould The picture above shows the slumping result with the highest melting point of 820 Celsius. The result shows that the glass sheets cracks due to the depth of the mould to be formed.

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Slumping Process The process of removing the glass sheets that has been slumped suing the mould to be taking off the mould took up a couple of stages to remove them. The following pictures shows the process of removing them after the results.

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Multi-Material Slumping Glass The picture above shows a multi-material of a slumping glass that has been fired at 820 Celsius with a firing schedule of 26 hours. The result shows brass filler turns blue when fusing them together at that particular temperature.

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350x350mm Slumping Mould Making Mould making is important and one of the main technical criteria in making sure that the firing of a glass is a success. The picture above shows the mould pattern that has been create using a formation of pattern on Styrofoam using CNC technology

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350x350mm Slumping Mould Making The pictures above show the mould making process and also the process of removing the Styrofoam pattern from the plaster and silica mould., The removing agent between these two materials is liquid latex.

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Metal Fusion on the Slumping Layers of Glass The slumping method requires a certain technique to fuse well with the metal filler. One of the techniques that we used to control the metal filler from spreading to far out from the dimension, we’ve used a liquid flux to control the spread. The picture above shows the result of the slumping method fused with 2 layers of 3mm glass.

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Glass and Metal Fusion with Slumping Technique Picture above shows the slumping result fused with metal by using two layers of 3mm glass and copper with a melting point of 860 Celcius. The result shows that when the copper melting with glass, it will turned blue and merged together with the glass at a very thin layer. Based on the research that we have done the temperature needs to hold longer to merge them well.

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600x1200mm Styrofoam Mould CNC technology has been used to create the mould pattern by using Styrofoam as the negative mould. The complex patter then will be used to create a mixed of plaster and silica mould.

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SPIDER CONNECTION FABRICATION

Glass and Metal Casting Process Glass casting is a process where you place glass in a mould to create a specific glass sculpture or design. The mould must be placed in a kiln to fuse the glass together and form your desired item. Casting glass is difficult and requires some specialist machinery. A proper safety precautions need when working with a kiln, wear kiln gloves and dark, protective glasses. The main challenge in this part is to create the 3D mould shape out of plaster and silica in order to cast it into glass. A lot of experimentation on various materials has been used to create the exact shape as the digital design. The technique that has been used including rubber mould technique to create the form out of wax then poured plaster onto it to cast the glass into it. With the help of technology like Ultimaker, there are varieties of filament out there to create the mould nicely and also bring a good impact to cut the costs of making, In this chapter explained the whole process of producing the spider connection glass using a series of mould making technique and also a lot of experimentation on the firing schedule.

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SPIDER CONNECTION Topological Optimization Designed

Throughout the research we have used topology optimization for

a series of process to create the designs that satisfy certain require-

ments, or objectives, and constraints. We have developed the tech-

nique for additional applications and the casting process for Glass and metal in various ways.

Topology optimization allows us to really explore our creativity. Tra-

ditional methods of architecture structural are mostly associated with

buildings that look like boxes. With topology optimization, we can address unique designs, for example, in our research we are focusing on improving the quality of the existing building skin. Synchronizing with

the research analogy to go against the discrete construction, we have

use this method to improve the existing spider connection systems by the implementation of FGM.

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Multi- Material Spider Connection The whole casting process in this part is the most challenging part to produce a multi-material of this spider connection come out in one piece. The picture above shows the shape of a multi-material spider connection that has been divide into two parts due to circumstances of the mould making process 280

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PVA Water Soluble Filament Ultimaker PVA (polyvinyl alcohol) is a 3D printing material commonly used to create water-soluble support structures to achieve complex geometries.

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Mould-Making Process Technical mould making process is important to make sure that the result is successful, Pictures above explains a series of mould making process to form this spider connection shape and convert it into a multi-material

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Behaviour of Glass when Heated The above diagram shows a broad overview of how the glasses act in different temperature ranges. All of the glasses do not behave identically following a certain rules and ranges. Some very slight variations can occur, depending on the viscosity of the individual glass. Furthermore,the specific kiln set-up , and firing cycle used will have a direct impact at any given rules. 286

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Graphics of the Slumping Firing Diagram The Slumping technique requires a specific pattern of firing schedule, the top temperature of every firing should meet the goal of the slumping digram describes the pattern of firing.

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CNC Negative Mould In conjunction of B-pro show, a 600x1200mm of glazing will be produced by using the slumping method , that has been justified throughout this chapter. The picture above shows a negative mould made up of Styrofoam to be poured plaster and silica onto it, before the firing take place. 289

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DIGITAL SIMULATION GRASSHOPPER This chapter is do series of digital simulation for our project. Main technique method is grasshopper. Use grasshopper to doing the structure generation and getting varies result can help us to inspire the design for the project.

“Physarum polycephalum, literally the ‘many-headed slime’, is a slime mould that inhabits shady, cool, moist areas, such as decaying leaves and logs. P. polycephalum is one of the easiest eukaryotic microbes

to grow in culture, and has been used as a model organism for many studies involving amoeboid movement and cell motility. For example, a team of Japanese and Hungarian researchers have shown P.

polycephalum can solve the shortest path problem. When grown in a

maze with oatmeal at two spots, P. polycephalum retracts from every-

where in the maze, except the shortest route connecting the two food sources.” (https://www.food4rhino.com/app/physarealm)

Based on this plug-in for grasshopper, we did those simulation.

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Emiter Boundary

Target

Physarealm Simulation 1 Set a box as the space which we need generate the structure. Then set two target points at the bottom, use three emitters generate particles to fill in the space and get the structure.

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Emiter Boundary

Obstacles

Target

Physarealm Simulation 2 Set a box as the space which we need generate the structure. Then set two target points at the bottom, use three emitters generate particles to fill in the space and get the structure with a obstacles inside this space.

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Emiter Boundary

Obstacles

Target

Physarealm Simulation 3 Set a box as the space which we need generate the structure. Then set two target points at the bottom, use three emitters generate particles to fill in the space and get the structure with a obstacles inside this space.

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Emiter Boundary

Obstacles

Target

Physarealm Simulation 4 Set a box as the space which we need generate the structure. Then set two target points at the bottom, use three emitters generate particles to fill in the space and get the structure with a obstacles inside this space.

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Rendering for simulation 4 Extract the central line in this model and use this lines to generate the structure

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Rendering for Simulation 4 Different views of rendering for this simulation

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Sub-structure for the Simulation Use the net to generate more detail for this shape and get a more interest result.

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DIGITAL SIMULATION REAL FLOW This chapter is do series of digital simulation for our project. Main technique method is Real Flow. Through the particles to simulate the liquid (gas, etc.) flow and collision, calculating the correct trajectory, and then using the particles to produce a smooth polygon mesh. The advantages of using particle system is can comply with fluid dy-

namics, able to embed materials data, able to set up the real gravity, etc.

What is particle system? Particle system elements are the points that have position, velocity, mass, and respond to the different forces,

but the main limitation is that it has no spatial extend as well as the absence of coherence and the constant changing of their positions within the simulation environment. Why choose particle system:

Easily import the materials data

Relatively small amount of computation

More suitable for fluid particle simulation This chapter is in order to do the research on material property.

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Frame 80

Frame 160

Frame 400

Frame 480

Frame 240

Frame 560

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Metal in Regular Points Simulation In this situation, the points are arranged in an regular way. It shows clearly that the metal material flows down and affected by the point object. Since the points are regular arranged that the fusing metal flow forms an regular net.

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Frame 80

Frame 160

Frame 400

Frame 480

Frame 240

Frame 560

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

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Frame 80

Frame 240

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

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Frame 80

Frame 160

Frame 400

Frame 480

Frame 240

Frame 560

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Wax in Regular Points Simulation Points are arranged in an regular way. It shows that wax flows down and affected by point object. Since the points are regular arranged that the fusing wax flow forms an regular net. As the net grow, the Influence of the object points is getting less. Wax won’t disperse at the bottom of the simulation. Instead, the wax will gathering as the simulation happening. 319

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Frame 80

Frame 160

Frame 400

Frame 480

Frame 240

Frame 560

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Wax in Regular Points Simulation Points are arranged in an regular way. It shows that wax flows down and affected by point object. Since the points are regular arranged that the fusing wax flow forms an regular net. As the net grow, the Influence of the object points is getting less. Wax won’t disperse at the bottom of the simulation. In stand, the wax will gathering as the simulation happening. 320

Frame 320

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APPENDIX

Frame 80

Frame 240

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Wax in Regular Points Simulation In this case, points are arranged in an regular way. It shows that wax flows down and affected by point object. Since points are regular arranged that the fusing wax flow forms an regular net. As the net grow, the Influence of the object points is getting less. Wax won’t disperse at the bottom of the simulation. In stand, the wax will gathering as the simulation happening. 321

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APPENDIX

Frame 80

Frame 160

Frame 400

Frame 480

Frame 240

Frame 560

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Metal in Random Points Simulation In this situation, the points are arranged in an random way. It shows clearly that the metal material flows down and affected by the point object. Since the points are random arranged that the fusing metal flow forms an unregulated net. As the net grow, the integrity of the net is getting less. At the bottom of the simulation, the metal material can’t form the complete net. 322

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Frame 80

Frame 160

Frame 400

Frame 480

Frame 240

Frame 560

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Metal Simulation When in the same situation, metal shows the same trait. It flows down and affected by the point object. Since the points are arranged organized that the fusing metal flow forms an regular net. As the net grow, the integrity of the net is getting less. At the bottom of the simulation, the metal material can’t form the complete net. 323

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

APPENDIX

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Wax in Random Points Simulation In this situation, points are arranged in random way. It shows that wax flows down and affected by the point object. Since the points are random arranged at the fusing wax flow forms an regular net. As the net grow, the Influence of object points is getting less. Wax won’t disperse at the bottom of the simulation. In stand, they will gathering as the simulation happening. 325

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Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Wax in Random Points Simulation In this situation, the points are arranged in an random way. It shows clearly that the metal material flows down and affected by the point object. Since the points are random arranged that the fusing metal flow forms an unregulated net. As the net grow, the integrity of the net is getting less. At the bottom of the simulation, the metal material can’t form the complete net. 326

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Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

APPENDIX

Frame 360

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Mixed Wax and Metal Simulation In this series of simulation, the influence points are totally same. The metal material is flowing on the left side while the wax material is flowing on the right side respectively. The position of the affect points is trying to lead the orbit of the materials that can full the container. It is clearly showing that those two materials can achieve this aim successfully. 328

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

APPENDIX

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

APPENDIX

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

APPENDIX

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

APPENDIX

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

APPENDIX

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

APPENDIX

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Multi-Emitter Simulation In this simulation, the emitters are effecting in an triangle shape container. The influence points are leading the flow direction of wax material that can full of the container.

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

APPENDIX

Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Different Shape of Container’ Simulation In this simulation, the two emitters are effecting in an diamond shape container. The influence points are leading the flow direction of wax material that can full of the container.

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Pre-Mixed Emitter Simulation In this simulation, the wax material and the metal material will pre-mixed before going into the container.

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

Pre-Mixed Emitter Simulation In this simulation, the wax material and the metal material will pre-mixed before going into the container.

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

3D Container Simulation In this series of simulation, the influence points are intend to lead the liquid, then it can change the direction of material and full the container in each side.

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Material: Metal Resolution: 0.3 Speed: 3.0 m/s Density: 0.26 g/cm³ Viscosity: 500 mPa·s/1400C Surface Tension:0.9 mN/m

Material: Wax Resolution: 0.3 Speed: 3.0 m/s Density: 0.95 g/cm³ Viscosity: 650 mPa·s/1400C Surface Tension: 20mN/m

3D Container Simulation In this series of simulation, the influence points are intend to lead the liquid, then it can change the direction of material and full the container in each side.

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Experiment process

Glass wax in random points box

Glass wax in regular points box

Experiment process 1 on Glass Wax and Metal Step one,using 5mm acrylic to form the a box as container. Then put a series of paper sticks as point objects inside the container in order to effect the flow of the material. Step two, the material are pure glass wax, pure metal and glass wax- metal mixture. Pouring those materials into the container seperately. 346

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Glass wax in random points box

Glass wax mixed metal in regular points box

Glass wax in random points box

Glass wax mixed metal in regular points box

Metal in regular points box

Glass wax mixed metal in regular points box

Metal in regular points box

Pouring Metal and Glass Wax on Different Points We set a series of different points in the box and let the liquid flowing down

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Model making process 1

Model making process 2

Experiment process 2 on Glass Wax and Metal Generate the gradient between the glass wax and metal layer, it clearly showing the transfer from glass wax to metal

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APPENDIX Material Gradient Using Thread to Represent

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APPENDIX Using Thread to Represent Material Gradient

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Adding extra materials to glass wax in order to increase its strength. 1. Glass fibre tissue. 2. Iron wet. 3. Chopped glass fibre. 4. Needled glass fibre.

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Brunches and glass model. Step one. 3D printing brunches model. Step two. Brushing glass wax and metal gradient on 3D printing model. Step three. Combine glass bottom and brunched together.

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