Acadia Submission - DHKLS

Robotically-Formed Geometry for Sand-based Architectural Castings

Timothy Sutherland Institution/Organization John Larmor Institution/Organization Mark Knutson Institution/Organization Grant Herron Institution/Organization Andrew Delle Bovi Institution/Organization

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PRODUCTION NOTES

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Our objective was to invoke a material with a high-embedded energy and innate structural integrity, aluminum, and exploit its relative low melting point, re-casting the metal for the production of customized, bespoke architectural components with novel tectonic and aesthetic qualities.

Architect:

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Client:

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Status:

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Site Area:

30,000 sq. ft.

Location:

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Aluminum’s current ubiquitous presence and relatively low cost for a metal make it a suitable material for such a process; the energy-intensive extraction and refinement of bauxite over the past 50-100 years has made aluminum amalgamated, now abundant on Earth’s surface as a shared human resource. In addition to the pre-embedded energy of aluminum and its low cost, the opportunity for architectural applications are versatile due to its high strength-to-weight ratio, weather-resistance, general low-maintenance properties, and relatively easily-achievable flow rates.

Equipment for the founding of aluminum is low-tech and easily fabricated; materials for sand cast mold-making are easily available, affordable and reusable. Melting recycled parts, from industries providing substantial quantities of pure and homogeneous discard material allows for plentiful material acquisition and forecasts a environmentally sustainable potential material for future practice.

Despite the long-established practice of melting and casting metals into bespoke parts, there are

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Clay-mixed sand receiving burnishing toolpaths to establish plane geometry.

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significant differences in this novel casting process which differentiate it from typical manufacturing processes. Most notably this process circumvents the necessity to create a ‘positive’, or to fabricate a version of the final form in another material, allowing for variability between parts cast opposed to the serial production of a single part.

Each cast part is formed in a 2-piece composite mold consisting of a top “cope” and bottom “drag”. A reusable bentonite (clay) sand and water mixture for the first “drag” half is given surface form through a burnishing tool process. By utilizing 7-axis, servo-driven robotic arms, fitted with custom-made tooling, computer-aided drawings and geometries were scripted into tool paths, transcribing the virtual concept into the physically manifest. The burnished clay half maintains a geometry dense enough to receive a negative counterpart of sodium-silicate bonded sand, which cures solid, and can be used to create multiple “blanks”, each of which can receive distinct tooling paths resulting in surface variation of a facsimile form. This solid half becomes

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Sodium-silicate mixed sand positive ready for robotic milling. (credits author

the “cope” half, which is paired with a new solid sodium-silicate sand “drag” half to complete the casting box. Once both cured, either (or both) halves undergo a unique rotary milling toolpath, providing part variability.

In traditional foundry technique the sprues, or the void which allows metal to flow to all parts of the casting is considered an unavoidable aspect of the process and are minimized and typically removed from the casting when it is complete. In our application the spruce system is maximized and becomes an integral structural and ornamental element. The sprue path matrix was designed using a mesh crawling script which allows the and even distribution of molten metal flow and allowes for increased tensile integrity across the surface of the global form.

Similarly, the flashing or the molten metal which flows through the small inevitable gaps between the two faces of the sand molds is generally considered error and is removed from the final casting. In our application this material process became a way to achieve extremely thin surficial castings which allowed for an

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Robotic inscription of panel perimeter geometry. (credits author lastname, date, Š if applicable)

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Discard aluminum car parts are brought to liquid in a 30 lb. crucible in a foundry.

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Sand mold split open to reveal cast aluminum panel. (credits author lastname,

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Variability through flow-rate variance in material and occurance of flashing.z

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Scripted patterning integrating swarf-cut joints, in final fluted column form.

intermittent reading of the global form The decided-upon architectural application was an ornamental and structural, fluted column; a twisting contemporary form which makes reference to late victorian / neo-gothic works which utilize cast metal in architectural form. The application of the final column inscribes swarf cut joinery and surface geometry ornamentation. The aesthetic tooling pattern was derived from a script which varies across the global form to respond to structural and aesthetic considerations.solor sapiducimaio voloreperum hitaspe lenditiust lit aliquas piendebit, od ut ad qui volore vel maximiliquo que ipsum laut landam quam quibus ut alibusandus idebis voluptatur sequaest, odis eostrum ipienihiciis eateMa dolut plantur reperat emquos quis eos aut pelecturia as nem quo blab imincieniet eos et aut repera dolentur?

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10 10-piece aggregated mock-up of ornamental, fluted column in cast aluminum.

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Project Title Author last names, separated by commas

11 Part Anatomy. (credits author lastname, date, © if applicable)

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12 Interlocking panel jointery, exhibiting ornamental and structural qualities.

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REFERENCES Authors should refer to both the Chicago Manual of Style, and the examples below.

[Book] Fox, Michael and Miles Kemp. 2009. Interactive Architecture. New York: Princeton Architectural Press.

[Book Chapter] Hasdell, Peter. 2009. “Pneuma: An Indeterminate Architecture, or Toward a Soft and Weedy Architecture.” In Design Ecologies: Sustainable Potentials in Architecture, edited L. Tilder and B. Bolstein. New York: Princeton Architectural Press. 92-113.

ACKNOWLEDGEMENTS TOPIC (ACADIA team will fill in)

[Journal Article] Brooks, Rodney A. 1990. “Elephants Don’t Play Chess.”

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