Terraperforma by Needlab

TERRAPERFORMA OTF 2016-2017 Research supervisors: Edouard Cabay, Alexandre Dubor

Research team: Raaghav Chenthur Naagendran, Sameera Chukkapalli, Iason Giraud, Abdullah Ibrahim, Lidia Ratoi, Lili Tayefi, Tanuj Thomas

INDEX

Acknowledgements

INTRODUCTION

HISTORICAL REFERENCES

STATE OF THE ART

MATERIAL

PRINTING and PERFORMANCE

CASE STUDIES

PERFORMATIVE WALLS

TECNALIA RESEARCH TRIP

MODULAR APPROACH

ANEXES

TerraPerforma is a project of IAAC, done under the tutorship of douard Cabay and Alexandre Dubor by Sameera Chukkappali, Iason Giraud, Abdullah Ibrahim, Raaghav Chentur Naagendran, Lidia Ratoi, Lili TayeďŹ , and Tanuj Thomas. The team was composed by a larger group of people, of which the OTF 2016-2017 team is thanking through this:

Computational Design Experts: Rodrigo Aguirre, Angelos Chronis Additive Manufacturing Expert: Sofoklis Giannakopolous Robotic Expert: Djordje Stanojevic Assistant Coordinator: Kunaljit Singh Chadha Assistant: Ji Won Jun Physical Computing Expert: Angel Munez Structural Engineer: Manja Van De Warp Architect for Earth construction: Wilfredo Carazas Aedo Physicist: Josep Perello Tecnalia Robotic Engineers: Pierre-Elie Herve Jean-Baptiste Izard Construction Coordinator: Gregoire Durrens Valldaura Coordinator: Jonathan Minchin

INTRODUCTION ABSTRACT TerraPerforma is a project of IAAC, Institute of Advanced Architecture Catalonia, developed at Open Thesis Fabrication in 2016-2017 by Sameera Chukkappali, Iason Giraud, Abdullah Ibrahim, Raaghav Chentur Naagendran, Lidia Ratoi, Lili Tayefi, and Tanuj Thomas, under the tutorship of Edouard Cabay and Alexandre Dubor. The project focuses on large scale, on-site 3D printing using clay as the building material. The project focuses on large scale 3D printing and the influence of additive manufacturing on a traditional material, while aiming to build a construction with performative design The construction parameters are given a functional context, the projects goal being to construct an edifice with performative behavior. The design is dictated by natural phenomena, in the sense that not only does it allow it, but it integrates solar and wind behavior into the design approach (the studied phenomena consisted in thermal conductivity, thermal convection, thermal mass, solar radiation and daylighting). Therefore, the approach of the project was multi-oriented, focusing on both the 3D Printing alphabet of design parameters, as well as the performative aspects.

OBJECTIVE The OTF Theme implied using clay as a contemporary construction material, using a state of the art approach. Mud constructions are an ancestral technique, based on the use of local material, with an ecological footprint close to zero. It is a material used worldwide, which allows significant winter heating and summer cooling, due to the thermal inertia properties. Additionally, due to their ability to absorb and evaporate, clay offers a self-regulating humidity environment, promoting a healthy indoor climate. However, while clay has been used in vernacular architecture for thousands of years, today it faces the stigma of being associated with only traditional or underdeveloped areas. However, by pairing it with contemporary technology, the aim of the project was to develop a prototype that would state clay as a plausible construction material for any type of architecture, relevant to the developing architectural field. The project combines 3 various postures of 3D Printing – Robotic fabrication, On-Site Printing and Printing with Clay, examples of which have been studied while developing the XXX Project. This proposal comes as a new addition to the additive manufacturing industry since not only it combines the 3 approaches into one, but the final aim of the project is building a performative edifice. While 3D printing has given the possilibity to create complex geometries, the intelligence of the design comes from the optimization strategies, the creation of performative shapes becoming easier to achieve. Additionally, by using AM we can witness a drastic reduction of the production of waste. Therefore, additive manufacturing with clay has the potential to not only introduce this material into contemporary culture, but to Based on the previous IAAC project Pylos, which discovered a new material mix of 100% naturally sourced and biodegradable elements and implied using a custom made extruder mounted on a robotic arm. The project was divided into robotic fabrication and the parameters which define it, and on creating a performative design demonstrating the qualities of clay in architecture. Therefore, after the robotic calibration aspects, the design was conducted by climatic phenomenon analysis. The shapes were built upon these parameters and then subjected to further optimization – each of the climatic aspects was dealt with separately, while the final design consists in a sum of all the divided research. The final design proposal is an optimized accumulation of researched topics, which resulted in a modular approach, which could be applied to both on-site and off-site printing. The premises of the program was met by focusing on the functional architectural elements, using robotic fabrication as a tool and not as a dictating element of the final design.

CLAY IN ARCHITECTURE HISTORICAL REFERENCES

Mud constructions have been erected for thousands of years. During the TerraPerforma project a series of these ediďŹ ces were studies, in terms of both performance and formal exploration, in order to optimize the current proposal.

WIND CATCHERS YAZD, IRAN, C. 3000 BC Since in arid and dry climates the daytime in summer is very warm and at nights cold, air trap was the speciﬁc feature of architecture in the majority of warm regions. The air trap operates with the change of air temperature and the difference of weight of inside and outside the trap. The difference of weight of the air impels a suction process which causes the air to ﬂow either to the bottom or to the top. © Dmitriy Christoprudov

BEEHIVE HOUSES HARRAN, MESOPOTAMIA C. 3000 BC Beehive homes stay cool in the desert heat. Their thick mud brick (adobe) walls trap the cool and keep the sun out. Beehive homes have few windows. The high domes collect the hot air, moving it away from the ground ﬂoor keeping the interior around 75°F (24°C) while outside extremes range from 95°F (35°C) to 32°F (0°C).

CLAY TOWERS SHIBAn. YEMEN, 1500 AD These houses have to resist the stresses of strong winds and minor shocks from frequent earthquakes since the 18th century. The door and window openings are few and small to minimize the sun’s glare and the movement of hot and cold air during the day and night. The roofs have a high-heatcapacity (the ability to store heat) to absorb the sun’s rays during the day and slowly release it to the interior during the cool night. © Editions Gelbart

CLAY IN ARCHITECTURE CONTEMPORARY REFERENCES

Mud constructions are still in use in contemporary architecture, either for entire ediďŹ ces or details design.

Nk’MIP hbbh architects, 2006 This nsulated wall stabilizes temperature variations. Constructed from local soils mixed with concrete and colour additives, it retains warmth in the winter, its substantial thermal mass cooling the building in the summer-much like the effect the surrounding earth has on a basement. Inslab radiant cooling and heating in both ceiling and foor slabs create an even, comfortable environment that avoids blasts of air, noise and dust © DIALOG

gallery facade archi union, china, 2016 The external walls of Chi She were built by the recycled grey green bricks from the old building and constructed with the help of the advanced technology of mechanical arm, which generates a cambered surface morphology. The positioning of the integrated equipment of robotic masonry fabrication technique makes this ancient material, brick, be able to meet the requirements in the contemporary era. © Su Shengliang & Bian Lin

EARTHSHIP Taos, new mexico An Earthship is a type of passive solar house that is made of both natural and upcycled materials such as earth-packed tires, pioneered by the architect Michael Reynolds. An Earthship addresses six principles or human needs: 1) Thermal/solar heating and cooling, 2) solar and wind electricity, 3) contained sewage treatment, 4) building with natural and recycled materials, 5) water harvesting, and 6) food production.[1] © Cynthia Ord

STATE OF THE ART ADDITIVE MANUFACTURING TECHNOLOGY - 3d PRINTING IN ARCHITECTURE While 3D Printing is not a topic of novelty anymore, the advancements in the ﬁeld are many and rapid. From building modular ediﬁces to large scale printing, additive manufacturing is becoming a topic of broader interest.

IAAC 3d PRinted Bridge Madrid, SPain The 3D printed bridge was developed through parametric design, which allows to optimize the distribution of materials and minimize the amount of waste by recycling the raw material during manufacture. The computational design also allows to maximize the structural performance, being able to dispose the material only where it is needed, maintaining the porosity thanks to the application of generative algorithms. © IAAC

BLOOM PAVILION Berkeley, 2015 Ronald Rael and UC Berkeley’s College of Environmental Design have created an innovative 3D printed building made from powdered cement. The Bloom pavilion is composed of 840 custom-printed blocks made from an iron oxide-free Portland cement polymer. It is the “ﬁrst and largest powder-based 3-D-printed cement structure built to date.”

ECHOVIREN SMITH ALLEN, 2013 Echoviren was fabricated, printed, and assembled on site by the designers. Through the use of a battery of consumer grade Type A Machines desktop 3D printers, Smith|Allen has constructed the world’s ﬁrst 3D printed, full-scale architectural installation. It is made of over 500 unique individually printed parts. The structure was assembled though a paneled snap ﬁt connection, merging individual components into a monolithic aggregation. © smith | allen studio

STATE OF THE ART ADDITIVE MANUFACTURING TECHNOLOGY - 3d PRINTING with Clay Before TerraPerforma. previous other experiments with 3D Printing with clay have been done. The team analyzed them ir oder to extract conclusions on which they can furthermore develop prototypes

MINI - BUILDERS 2016 Minibots work essentially the same way as their crane-sized counterparts and deposit layers of liquiﬁed build material. The primary difference is a more modest scale and a very different design approach. The core of the system is still a bulky master unit that houses two large cylinders of liquiﬁed, synthetic marble specially formulated by Jokić and Novikov.

CLAYSTRUDER 2015 The Claystruder project is part of the digifabTuring research. They have developed an hybrid extruder system to print clay and other dough, that they use with a COMAU NJ60 anthropomorphic arm.

GCODE CLAy Emerging Objects, 2016 GCODE.Clay is a series of objects 3D printed in various clays that explore the creative potential of designing with G-code. In this case the 3D printer is pushed outside the boundaries of what would typically deﬁne the printed object, creating a series of controlled errors that create a new expressions in clay (see more about errors in anex 2) deﬁned by the plasticity of the material, gravity and machine behavior © Rebecca Jay

MATERIAL PROPERTIES of CLAY Clay is a fine-grained natural rock or soil material that combines one or more clay minerals with traces of metal oxides and organic matter. Properties of the clays include plasticity, viscosity, contraction or shrinkage, fineness of grain, hardness and cohesion, all of which can, in this case, be considered both properties and difficulties to deal with while printing. Clay is colorless, but its color depends on the soil content where it is deposited, varying from white, grey, black or red brown. Clay is generally made from mixtures of clay or other substances, and in the TerraPerforma case a series of other substances were added in order to make it usable, such as gelatin, water or hexametaphosphate. Due to the plasticity of the material, it is easily molded into a form that remains basically the same when dried, taking into consideration shrinkage or buckling (see structure chapter). However, when dried, all plasticity properties are no longer present. In architecture, clay has been used for millennia and is one of the oldest building materials known. Two thirds of the world still live or work in buildings made with clay. It is technique with an ecological footprint close to zero. It requires a very small amount of embodied energy, it can be recycled, and it allows naturally to heat in winter and cool in the summer, due to the thermal inertia. Clay architecture is also advantageous since it can self-regulate humidity in the indoor environment, due to the material’s property of absorbing and evaporating. While in the contemporary design scene clay is more used for detail design such as clay plaster, clay floors, clay paints or as a ceramic building material, the aim of the project was to re-use it in its ancestral methods, as a large scale building material. By manipulating the material’s properties, it could be noticeable that for example the increase in proportions of water and each additive would damage the clay quality – the optimization exercise consisted in maintaining high viscosity with the least amount of water, achieved by adding fibers which would encapsulate the humidity within the material bonds, thus allowing the material to contract less but still have an even consistency and high strength.

MATERIAL STRENGTH

While clay is a maleable material and can be manipulated into various geometries, the question of strength is vital since it is within the context of architectural building. Due to not only formal divagation, but also various material mixes, the strength of the prototypes varies.

MATERIAL PROPERTIES

CALCerous clay

red clay

1020 C

clay micronitzada 1020 C

1000 C

Modelling Large Size Creation

Thowing Without Chamota

Fine Arts Craft

Chamota 0-0.1:5 MM

CBP=P High viscosity Medium density High water content (not controlable) Price 0.996 Euro/kg

Without Chamota

FP CH 0=0.2mm

Clay micronitzada

Medium viscosity High density High water content (not controlable) Price 0.576 Euro/kg

Fine Granules High density No water content (controlable) Price 0.40 Euro/kg

STructural strength

PRINTABIlity Parameters Line

Viscosity

Structural Strength Drying Period

Water Absorption (g/mm sq./sec)

Shrinkage By Material Mix

Viscosity (visual)

Stickyness (Physical)

Drying Period (days)

Water absorption coefficient

Shrinkage %

Strength Comparison

1.16 0.915 1.26

Tensile Strength N/mm sq.) Breaking Point (Bars)

2.1

1.7 3 1

Clay CBP + Hexamataphosphate + Saw Dyust Clay + Sand + Hexamataphosphate + Saw Dust + Gelatin Clay Pasta CH C 0-0.2 mm + Hexamataphosphate + Saw Dust

Clay FP-CH 0-0.2 mm

Clay CBP-P + Hexamataphosphate

Clay FP-CH 0-0.2 mm

Clay CBP-P + Hexamataphosphate + Gelatin

Clay FP-CH 0-0.2 mm

Clay CBP-P + SawDust

Clay FP-CH 0-0.2 mm

Clay CBP-P + Hexamataphosphate + SawDust

CONCLUSIONS

After various tests done with a number of materials added to the basic clay, it could be evident what the perfect ratio between materials such as hexametaphospate, water or gelatine is. The proportions are vital, since adding more or less water could overincrease the drying period or damage the viscosity of the material.

ADDITIVE MANUFACTURING And PERFORMANCE

Additive Manufacturing (AM) is a 3D Printing technology which implies building objects by adding layer-upon-layer of material. It is used for plastic, metal, concrete, glass or even cells. It is increasing in popularity due to the liberty of geometrical exploration it allows, as well as the structural stability due to the layer-upon-layer technique. In this case, the material was optimized in order to make AM possible. The printing was possible due to Pylos, a research action done at IAAC by Sofoklis Giannokopoulos, which resulted in the development of an extruder with a canister of 15 L, compressed with a pneumatic cylinder. The extruder’s measurements 300x300x2000mm. It allows printing with a layer thickness between 1 and 7 mm, 6 to 30 mm in width, at a speed between 0.05 and 1 m/s. However, clay is not used only for its physical properties, but for its thermal inertia properties. During the project, thermal conductivity, thermal mass, thermal convection, solar radiation and day lighting have been analyzed and incorporated into the 3D Printing language, in order to conclude in a optimized, performative ediﬁce. The results were successful both in terms of performance, and in terms of highlighting 3D printing properties. The formal exploration was given a clear context, therefore the exercise was neither a case of extreme form ﬁnding, which implies only digital research without any functionality, nor form making, which implies solely problem solving. Within an architectural context, the wall prototypes prove functionality and feasibility, while also demonstrating AM potential.

CONTEXT Three different natural sites were analyzed, in various locations of the world, with different climatic conditions. In each of these sites there are historical and contemporary clay houses, proving that mud buildings are a technique with worldwide use. The proposed sites are Bucharest, Romania, because of extreme climatic conditions (in the winter, temperatures go to -25 Celcius degress, and in the summer up to 45 Celcius degrees). The ideal scenario is in Yazd, Iran, due to climatic conditions (long, hot, dry summers and winter temperatures dropping only to minimum 5 Celcius degrees) , while the proposed site for the ďŹ nal prototype is Valldaura, Spain, due to the fact that it is the most approachable for IAAC students, being located outside Barcelona, therefore could permit on-site printing.

Psychometric Chart bucharest, romania 1 JAN 1:00 - 31 Dec 24:00

yazd, Iran 1 JAN 1:00 - 31 Dec 24:00

VALLDAURA,SPAIN 1 JAN 1:00 - 31 Dec 24:00

HOURS 97.00 <= 87.30 77.60 57.90 58.20 48.50 38.80 29.10 19.40 9.70 <=0.00

REFERENCED PROJECTS Two projects combining Addivitive Manufacturing and Clay have been previously conducted within IAAC. Pylos, by Sofoklis Giannokopoulos, resulted in the development of an custom-made extruder with a canister of 15L. FabClay, conducted by Sasha Jokic, Starsk Lara, and Nasim Fashami, provided an extensive research source for material behavior paired with robotic fabrication. Additionally, in the beginning of OTF, the student researchers were able to work with Sofoklis Giannokopoulos to better understand the parameters they were given, during a two week workshop, let alongside Djordje Stanojevic.

MACHINE

{FabClay}

pylos By: Sofoklis Giannokopoulos (Greece) The project focuses on the difficulties of the concept itself, that needs to be further developed, however after the ďŹ rst stages already revealing impressive results. The development, starting from basic composites towards more laborate ones, contemporarily to to the development and anufacturing of the machine, driven by the research and results on the material behaviour, reveals the protocol towards the abrication of the ďŹ nal machine. In this sense, one impressive material result that illustrates the power of material science was chosen, and a couple of extruders were then developed to print with this particular material. The interest to develop printing as a construction method, oreover when printing with natural materials, particularly in this time of economic and environmental crisis, is undeniable. The material results obtained through the development of the ďŹ rst phase of this research project are extremely promising, and consequently push the interest towards the further development of the machine itself.

FabClay By: Sasha Jokic (Serbia), Starsk Lara (Colombia) and Nasim Fashami (Iran) FabClay is a project done by Sasha Jokic (Serbia), Starsk Lara (Colombia) and Nasim Fashami (Iran) ,based on the idea of robotic additive manufacturing fabrication, innovative materials and computational tools. The reserach aimed to exploring a new digital fabrication system which is fully optimized, adaptive and human independent system. It has started from researches on traditional way of building with simple and accessible materials and continued by expanding the connections between architecture and new technology. Through digital design process we are able to make complex shapes by simple rules that are emerging from mechanic performance and materialâ&#x20AC;&#x2122;s possibility.Materialâ&#x20AC;&#x2122;s properties and its communication with machines will create the performance in which complex forms can be emerged, therefore exploring the behavior of material and itsâ&#x20AC;&#x2122; potentials give rise to develop prototypes in order to achieve architectural applications in variation of species in terms of scale, form and function.

PERFORMATIVE WALLS

The ďŹ rst stage of the project resulted in the extended research of various types of performative walls. Within this research, thermal conductivity, thermal mass, thermal convection, solar radiation and daylighting were analyzed, in order to incorporate climatic phenomena into 3D printing. Each phenomena implied a different kind of formal variation, a different kind of inďŹ ll, various types of openings, textures or continuity of the line (see Anex 2 and 3). The walls were generated in order to permit both wind and solar behavior. For the optimization of these, software such as Karamba, Ladybug, Heliotrope, Rhino CFD was used in order to digitally simulate the outcome. Additionally, a higrothermal monitoring apparatus was build, in order to test the results of the physical prototypes. In this stage of the project, the structural reasoning was also established. Different type of curvature was tested, as well as different type of extrusion: straight, tapered or concave, in order to see the material behavior and the structural limits.

thermal conductivity

In physics, thermal conductivity is the property of a material to conduct heat. It is evaluated primarily in terms of Fourierâ&#x20AC;&#x2122;s Law for heat conduction. Heat transfer occurs at a lower rate across materials of low thermal conductivity than across materials of high thermal conductivity. Correspondingly, materials of high thermal conductivity are widely used in heat sink applications and materials of low thermal conductivity are used as thermal insulation. The thermal conductivity of a material may depend on temperature. The reciprocal of thermal conductivity is called thermal resistivity.

k1 k2

CONCLUSIONS

The key question one needs to address is that during a day circle how much thermal lag is required for the space in question, to be considered comfortable. If a greater quantity of thermal lag is needed, this means that a great quantity of thermal resistance is needed. Therefore, by maximizing the actual length that the energy travels, by longer paths and geometries of material deposition and distribution inside the width of the wall we can achieve low rates of conductivity.

convection

Convective heat transfer, often referred to simply as convection, is the transfer of heat from one place to another by the movement of ďŹ&#x201A;uids. Convection is usually the dominant form of heat transfer in liquids and gases. Although often discussed as a distinct method of heat transfer, convective heat transfer involves the combined processes of unknown conduction (heat diffusion) and advection

CONCLUSIONS

Wind channells have proved to be the optimum choice of taking maximum advantage of thermal convection, directing wind in an intelligent way. The wind channels also optimize 3D Printing time and performance - the top point of the under opening ellipse is positioned at the same level as the bottom point of the upper opening ellipse, therefore the print uses a continous toolpath line, avoiding the On/ Off command which was typically used to create openings.

heat simulated inside the box

heat simulated outside the box

thermal analysis

41.2

TEMP

TIME

180

240 MM

Sensor reading next to the simulated environment

basic wall

Sensor reading after the prototype

40 TEMP 0

30.9 TIME

240 MM

wall with heat sink diffuser

CONCLUSIONS

The thermal camera depicts the thermal conductivity over the inďŹ ll, thus it become easier to depict where higher thermal mass is depicted.

IN CI DE N

SU N

RA Y

solar radiation

Solar radiation is radiant energy emitted by the sun, particularly electromagnetic energy. About half of the radiation is in the visible short-wave part of the electromagnetic spectrum. The other half is mostly in the near-infrared part, with some in the ultraviolet part of the spectrum

RE FL EC TE

WALL SHADOWS

RA YS

CONCLUSIONS

DiďŹ ferent angles of inclination of surface detail were tested in order to ďŹ nd the maximum self-shaded area possible. It was tested for summer and winter vectors, and an average optimum of inclination was chosen.

DAYLIGHTING

Daylight, or the light of day, is the combination of all direct and indirect sunlight during the daytime. This includes direct sunlight, diffuse sky radiation, and both of these reﬂected from the Earth and terrestrial objects. Sunlight scattered or reﬂected from objects in outer space is not generally considered daylight. Thus, moonlight is never considered daylight, despite being “indirect sunlight”.

SUMMER SUN

WINTER SUN

Conclusions

After a series of digital and physical tests, it was decided that while it may seem that larger openings provide more daylight, a series of small openings was a better choice, due to the fact that in can be directed in order to avoid overheating, thus being a stable choice regarding 2 climatic phenomenons. The direction of the inďŹ ll is dictated by sun vector. The direction of the opening is dictated by anchestral techniques which deviate summer sun and permit winter sun.

STRUCTURAL BEHAVIOR

Since the project implied working with both a new material and a new method, an extensive part of the research was dedicated to structural analysis. Using both digital tools such as Karamba to determine structural strength, as well as physical prototyping and a load testing apparatus, the team was able to develop a new structural alphabet.

BUCKLING

Buckling is characterized by a sudden sideways failure of a structural member subjected to a high compressive stress where the compressive stress at the point of the failure is less than the ultimate compressive stress that the material is capable of withstanding

Load

Horizontal shear stress

Compression

F= maximum or critical force E= modulus of elasticity I = area moment of inertia of the cross section of the rod L = unsupported length of the column K = Column effective length factor

Vertical shear stress

Tension

MASS : 20 LOAD : 30

MASS : 30.3 LOAD : 30.3

MASS : 37 LOAD : 61

MASS : 28 LOAD : 21

MASS : 24 LOAD : 89

MASS : 42 LOAD : 1150

Without the unsupported length segmented the maximum load it could take is less

One side being equally divided it carries almost the same load without the lenght segmented

Dividing both vertical members help the structure to carry almost double the load

Vertical member does not perform efficiently

Horizontal member dividing the unsupported length provides more support

Supporting the corners beside dividing the length would gave a more stable structure

Conclusions

Double curvature geometry gives the most stability and it can resist big load acting perpendicularly to the middle point.

Shrinkage

Shrinkage occurs due to the material properties. Changes of pore water content due to drying or wetting processes cause signiďŹ cant volume changes. Drying shrinkage at high humidities is caused mainly by compressive stresses in the solid microstructure which balance the increase in capillary tension and surface tension on the pore walls. In this case, it needed to be optimized because in could cause line intersections could be overly fragile and break. Also, although the lines may touch when wet, due to shrinkage, once dried, they could become to further appart.

Breaking every breaking every 15-20 cm 15-20 cm

Length length Starting startinglength length

contraction is relative to Î&#x201D;l and geometry

lengthafter after contraction Length contraction Î&#x201D;l

Open Thesis Fabrication 2016/2017

Structural Workshop

Breaking every breaking every 15-20 cm 15-20 cm

No failure at touching

faillure at intersections Failure at intersections

no faillures in touching lines intersections intersections

INTERSECTIONS

Because of material shrinkage and breaking, the intersections had to be optimized. The point of contact was continously changed throughout the tests, both digital and physical, in order to be able to develop a strategy for a large scale prototype. The software tests, done using structural analysis programming such as Karamba for Grasshopper, were always paired with physical tests, in order to establish the limit in which analysis can rely on digital means.

test 1

test 2

test 3

test 4

1 point of contact

2 points of contact

overlap

overlap and knot

displacement: 3.1 e - 03 cm

displacement: 3.2 e - 03 cm

displacement: 3.1 e - 03 cm

axial stress: 1.22e - 2 KN/cm2

axial stress: 1.66e - 2 KN/cm2

axial stress: 1.89e - 2 KN/cm2

axial stress: 1.55e - 1 KN/cm2

Conclusions

Since the material is wet when extruded, when it dries it is not convenient for overlapping intersection. When the shrinkage occurs, the nod between the two intersections causes breakage due do the lack of mobility created within the geometry.

LOAD TESTING APPARATUS The team created a series of machinery in order to physically test their prototypes. The load bearing machine is designed in order to see how much weight the wall prototypes of 30x40x20 cm can support, in order to further create strategies for the big scale prototypes.

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CASE STUDY no 1 TECNALIA RESEARCH TRIP

The OTF researchers had the opportunity to work for one week in the Tecnalia factory in Montpellier, using the CoGiro Cable Bot. Cogiro is a CDPR owned by Tecnalia and LIRMM-CNRS. Its original point of design resides in the way the cables are connected to the frame, called the conﬁguration of the CDPR, which makes is a very stable design. It is also the biggest CDPR in Europe, with a footprint of 15x11m, 6 m high, and capable of holding a load up to 500 kg over more than 80 % of the footprint. Advances in the control of the robot have allowed to reach repeatability in the milimetric range and precision in the low centimetric tange. This implied an entirely new set of robot calibration and of conclusions based on testing. The shape is dictated by a continuous toolpath, in order to control the direction of the tool. The next step was to create a design that uses intersections which don’t overlap, but touch at maximum curvature point (a solution emerging from the intersection tests). The last parameter was creating almost a modular approach, in the sense that the toolpath doesn’t go all the way around the volume, but self-ﬁnishes each wall individually. The new approach also implied using double-line walls, in order to support the weight of a larger wall.

INFILL STRATEGY

The inďŹ ll pattern is dictated by thermal properties logic, as well as taking into consideration large scale 3D Printing. The intersection are designed to touch each other but not overlap, since it was causing breakage in a prototype of this size. The toolpath ďŹ nished each wall individually, in order to avoid losing moisture of each line before extruding the next one, so that the different layers of print bond well.

200mm 200 mm

415415mm mm

386 mm 386 mm

200mm 200 mm Period Period

792 mm 792 mm

Period Period

Prototype Prototype 01 01// wall 1 wall 1

200mm

Prototype Prototype02 02/ / wall 2 wall 2

200 mm Period 200mm

mm 415 415 mm

Period

386 386 mm mm mm 792792mm

Period

Period Period

CASE STUDY no 3 MODULAR APPROACH

For the final stage of TerraPerforma, it was concluded that a modular approach would be best. The modules are parametrically conceived so that they have optimum performance depending on solar radiation, wind behavior and structural 3D printing reasoning, both by their own and as a whole design. The façade was conceived as a gradient in both horizontal and vertical directions, having various radiuses of self-shading, in order to optimize east and west sun. Additionally, the modules are designed to incorporate various types of openings, in order to maximize the natural daylight potential – the openings are strategically placed and vary from micro openings to full openings between bricks are light channels. The same channels are also designed to aid wind behavior through convection properties, as well as the placement of the microperforation which would direct air flow. The infill of the modules is parametrically conceived so that the upper modules consist in a lighter infill, in order to ease the structure (each module is encapsulated in a grid of 44×16 cm). The modules are also designed in order to create a concave elevation, which after various solar and wind analysis, both in digital media and in physical prototyping, has been proved as being the optimum shape.

Sun Analysis during summertime for a concave wall with exterior surface consisting in rhomboidal modules

Sun analysis

The facadeâ&#x20AC;&#x2122;s aesthetic is dictated by solar radiation deďŹ&#x201A;ection strategies. While in the summer the surfaces of the wall needed to be able to be cool, in winter time over-cooling must be avoided. The modules needed to be created as an optimization of solar radiation, so that they would ensure a pleasant inside environment.

Sun Analysis during winter time for a concave wall with exterior surface consisting in rhomboidal modules

CONCLUSION

The diamond shaped modules proved to be the optimum shape to be used, after extended research and sun analysis using Lady Bug software.

FACADE

The ďŹ rst stage of optimizing the modules was to vertically divide the rhombuses in two modules, in order to be able to create large shading elements. The second step was to create a strategy for each of the facade rhombuses to change horinzontally, in order to create a gradient which will maximize solar radiation deďŹ&#x201A;ection. There are 5 module variations, intertwining 3 types of rhombus sizes. There are modules with 2, 3 or 4 rhombuses, but also modules incorporating half size rhombuses where in the second half of each module the rhombus size shrinks from left to right according to the next module stacked on top of it

CONCLUSION

While there is a lot of possibility of deviation in rhombus sizes, this strategy was chosen to the possibility of the inďŹ ll coinciding, therefore the modules could be easily assembled vertically. Additionally, the broken vertical rhombuses required a facile way to be stacked in order to ďŹ rmly recreate the diamond shape.

INFILL STRATEGY

The infill logic strategy is dictated by thermal properties. The layer towards the exterior is the one defining the 2, 3 or 4 rhombuses on the facade, which provide self-shading against solar radiation. The middle layer acts as heat sinks, proving thermal conductivity within the wall. The last layer hosts the heat capacitors and heat diffusion. Towards the interior the wall is straight, to counterbalance the rhombuses. The modules fit together horizontally through male-female joints, designed to easily assemble the bricks.

CONCLUSION

Line length was also optimized, in order to be able to print every module with two tanks of material. Additionally, there are both overlapping and touching intersections, depending on the lenght of the straight line and the placement within the inďŹ ll (towards the interior or the exterior).

Modular Infill Logic

Plan of module A1 Location: building SW corner, layer 0 Module A1 Inside

ale

joi

depth: 350 mm

fem ale join t

width: 420 mm

period: 209 mm element: 105 mm

Robot & Extrusion Velocity: 0.12 m/s Air pressure: 7mPa

layer 56 height: 168 cm

layer 28 height: 84 cm

layer 0 height: 0 cm

Module A2

Material Line width wet: 11 mm Line witdth dry: 7 mm Toolpath length: 5.8 mm Module weight wet Module weight dry Module volume: 0.025 m3

OPENINGS For the development of the final edifice, which is to function as a performative building, the walls required to present apertures, for convection reasoning and to permit the maximization of daylight potential. Additionally, since architectural, even experimental one, has traditional elements such as a door, windows, sky lights etc, strategies for incorporating all of these elements were created. Due to 3D Printing reasoning, which demands specific types of geometrical approach, considering its specific technical requirements, 3 types of openings were developed: 1) Microperforations 2) Windows 3) Interior channeling

Windows Use of On/Off technique

MicroPerforations Deviating Continous Line

Interior Channeling Double wall technique

1) Microperforations Microperforations are created through a continous line through the infill layer print, which at one point in the trajectory gets deviated, thus creating an opening. (details in Anex 2). 2) Windows Windows require the use of the On/Off robot command (details in Anex 2). Therefore, within the same surface is is possible to obtain a “through-and-through opening”. 3) Interior channeling Interior channels are created by designing a specific type of infill, which as the layer height increases start to come together or appart, creating tunnels within the infill pattern.

Modular Infill Logic

Plan of module A1 Location: building SW corner, layer 0

CATALOGUE OF MODULEs

Axo of 55 individual modules Ordered in print priority

Terra Performa Section A location: building SW & SE wall Section A Location: building SW & SE wall

Fastening Joint

2416 mm

Fastening Joint

11 mm OSB

40 mm Foam

780 mm

Detail Detail BB

Detail C C Detail

7SHU ZJHSL ! Plan (scale 1:400)

6WLU ;OLZPZ -HIYPJH[PVU 0UZ[P[\[L MVY (K]HUJLK (YJOP[LJ[\YL VM *H[HSVUPH

Edouard Cabay, Alexandre Dubor

775mm

OSB 11 mm mm OSB 11 Wooden sticks Wooden Sticks 34 34 mm mm Wooden Sticks 34 34 mm mm Wooden sticks

Fastening Joint

Fastening Jo

34 34 mm mm wood sticks

wooden stick

Capacitors Capacitors

ZJHSL ! Detail A scale 1:25

Hinge Hingedetail detail 45detail cut 45 cut detail

DetailA A Detail

4040 mmmm wooden stic wooden

stick

Detail 1:25 DetailBBscale ZJHSL !

EPDM EPDM Deta Detail

OSB 11 mm OSB 11mm

Local Stone Local Stone

Fastening Fastening J Joint

ZJHSL ! Detail cC scale 1:25

Gravel Gravel

Final prototype

The ďŹ nal prototype was built in the Valldaura camp. The team created a stone foundation for it, using rocks from the Valldaura quary. Also, all the materials used were from the local site: the wood for the scaffolding, the rocks, the mortar mix (consisting in only soil, gravel and water).

FURThER DEVELOPMENT

Beyond what the team has allready printed and assembled, TerraPerforma is an on-going study and the researchers have a ďŹ nal proposal for the ediďŹ ce. The to-be-build part of the project respects the same logic, uniting within the same existence additive manufacturing and performative aspects. Each wall is individually designed to have optimum performance considering climate behavior. The interior of the ediďŹ ce is designed to have a similar structure to the existing houses surrounding the Valldaura mansion. However, the house can be designed to accomodate any type of site, a premises proven due to OTF 2016-2017 research. While there are limitless possibilities of deviation, from modular approaches to big continous toolpath printing on-site, the team focused their efforts in transforming the existing modular approach into a fully functioning house prototype.

FLOORPLAN

The ďŹ&#x201A;oorplan was designed to immitate the existing layout of the spanish houses located in the Valldaura Can. Combining natural materials and simple geometries, the ediďŹ ce offers a comfortable environment.

Facades

Every facade is conceived in order to optimize the climatic phenomen surrounding it, depending on orientation. The openings are strategically placed, in order to maximize daylight and inďŹ&#x201A;uence wind direction.

ANEX 1Climatic Phenomena iterations

In order to better undestand the circumstance of the climatic phenomena studies and create an optimum series of design proposals, the group conducted a lenghty research regarding each natural phenomenon and, additionally, a series of structural iterations. Each series of iterations contains a minimum of 10 formal variations in order to have a scientiďŹ c base conducted by empirical methodology. The phenomena studied consisted in thermal conductivity, thermal mass, thermal convection, solar radiation, daylighting and structual reasoning. Each of the iterations was simulated digitally and based on this 2 optimum walls were printed.

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inďŹ ll 6 0%

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th pa gy r er ito en h ac of pat rea cap a f ce of rfa t ive ) o su gh ct (k 1: len du nt er : on ta et r 2 : c ns m te 3 o ra e er 4: c Pa ram et er Pa aram met P ara P

inďŹ ll 1 00 %

re e

inďŹ ll 4 0%

td eg

ion

ra t

ite

gr ee

3r d

de gr ee

3 2n rd d d d eg eg ree re fr e b on ac t k

3 co rd d nd eg uc re tiv e f e c ro av nt ity 25

% ,c ap 1

3 co rd d nd eg uc re tiv e ec av ity

% ,c ap 3

10 % ,c ap 2

3 co rd d nd eg uc re tiv e f e c ro av nt ity 24

c p ase op atte stu tim rns dy ize ba _co d s se nd rf d o uc n s tive ola r in pu t

th pa gy er en h of pat r ce of cito rfa t a su gh ap 1: len t c ink er : ea s et r 2 : h at m te 3 e ra e er 4: h Pa aram met ter P a e r Pa aram P

th pa gy er en h of pat ce of rfa t su gh 1: len er : et r 2 m te ra e Pa aram P

phenomenon : Thermal Conductivity 3 co rd d nd eg uc ree tiv ec av ity,

ca p

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phenomenon : Thermal Convection

a thr ir ch ou am gh b ou ers tw all

Scale : 1:15 Print speed: 0.12 m/s Print height: 3 mm

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Phenomena: Daylighting Design Iterations of Wall Concepts

Open Thesis Fabrication 2016 - 2017 Institute for Advanced Architecture of Catalonia Edouard Cabay, Alexandre Dubor Abdullah Ibrahim, Sameera Chukkapalli, Tanuj Thomas, Lili Tayefi, Chenthur Raaghav, Iason Giraud, Lidia Ratoi

w rf ce Su rfa d su rve ed Cu rv Cu

phenomenon : Daylighting

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Scale Print: 1:15 speed: 0.12 m/s Print speed: 0.12 3 m/s Print height: mm Print height: 3 mm Print width: 7 mm

Print pressure: 7 mPa

se ba n ed io rv at cu lev ith ht e s w aig all tr W s e d an roﬁl p

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phenomenon : Solar radiation

Fu ll S oli dW all

Scale : 1:15 Print speed: 0.12 m/s Print height: 3 mm

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In m ďŹ ll an su ipu rfa lat ce ion

M No ultip n - le l Ex ine tru de d

phenomenon : Structure InďŹ

Fo int lds ers m ec irro ted red pa tte rn s

M Ex ultip tru le de lin d e

G int ear m ers i ec rror ted ed pa tte rn s Cu

Fo pa lds tte | Tw rn o s

S Ex ingle tru lin de e d No n

m irro red

C pa urve tte s | rn Tw s om irro red

Int ers ec tio n0 1

2P oin ts

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fol ds

St r

Int ers ec tio n0 2

Fo lds

To uc hin g

Ge ar pa tte rn

Cu rve s

Scale : 1:15 Print speed: 0.12 m/s Print height: 3 mm

m ďŹ ll an su ipu rfa lat ce ion 2

Fri cti on

C Le antil an ev ing er -

int urve ers s m ec ir ted ror pa ed tte rn s

O Ca pen nti ing lev s er

H lap exag pin on g o al p ne att ed ern ge | o ve r-

O Ca pen nti ing lev s er 2

Cu rve st ou ch ing po int s

m retc irro he red d g pa ear tte pa rn ter s x2 n | T wo

He xa go na lP att ern

S pa ix fol tte ds rn | T s w x2 o m irro red

Ov erl ap pin g

30 cm

In t

er s

ec tio

ld s

phenomenon : thermal mass

Phenomena: Structure

ANEX 2Line studies

The initial stage of the project implied a heavy research regarding robotic calibration. The categories were divided into : Line. Line in Space (texture), Cantilevers and Overhangs, and On / Off. The research was done for small scale prototypes, in order to be able to conclude in an alphabet of design parameters, that would be furtherly developed and prolongued when increasing the scale of the prototypes the team was developing. Each of the following categories resulted in its own set of tests and conclusions. This analysis was done during a workshop conducted by Sofoklis Giannakopoulos and Djordje Stanojevic.

Line

The line test were primarily focusing on the continuity of the line, creating an un-interrupted toolpath. The tests then continued to branching simulations. An optimum ratio between lines width and length was discovered. Then these lines were subjected to various degrees of rotation that generated overlapping, intersections, continuous lines and symmetry in order to maximize the cleanliness of the models.

Inside

Outside

A1_layer height: 3 mm A2_no of layers: 9 A3_print width: 6.5 mm

CONCLUSION

Elevation Branching was done in a series of ways. It started with a model that had a Boolean intersection in the top, but the bottom was hollow and had many cantilevers, which was a strategy that failed. The second geometry wasn’t exactly branching, but there was an opening and a single contour line. A relationship between inside and outside was established, with a crossing intersection, so it opens where it touches itself. The intersection worked, the prototype was uneven due to chosen pressure and speed. The third model’s surface is a lot more consistent because of the addition of cantilevers. The ridges are even, and speed and pressure are optimized for further use. In the fourth model, a different material was used, therefore a form with two types of intersection was possible – one that crosses and one that allows modules to touch each other.

Plan

ON / OFF / WAIT

The On/Off/Wait commands refer to the material being stopped from extruding within the same code of printing. This is helpful for creating intersecting shapes or openings, since it gives the possibility to basically stop printing within the line. However, if the extrusion is abruptly stopped, there is a cluster of material at the end of the line, so the WAIT command is introduced, in order to graduately stop extruding. The duration of the On/Off/Wait commmands had to be optimized, as well as the location of the WAIT point.

Time proportionate to material width / length

Material

Material width

Origin of line

CONCLUSION The ON/OFF tests started while creating a column, with the challenge of intersecting in planimetry two identical shapes, and place the seam and ON and OFF command on the inside of the structure, so that it will hide fabrication flaws, since in architecture and design the manufacturing process’s importance and flaws succumb to the importance of the final, clean product. The shapes were derived and played with the two basic squares that were intersecting – their edge were filleted, in order to create a more organic shape. A route that would permit them to come apart and then intersect was created. Along the curve the squares were scaled, bigger towards the bottom and leaner towards the tip, for structural purposes, and rotated in XY plane, to create a twisted effect.

0 Corner ﬁllet r=5 Translation from 0-104 Center Axis Direction of Deposition Material Width - 8mm

Origin of line Seam Wait position - End

Wait position - end

End point of toolpath

LINE IN SPACE

Types of lines were continously tested in order to derive the curvature of the lines into a structural element. Texture bumps became place holders for the curveâ&#x20AC;&#x2122;s seam, undulating shapes were given a context within architectural elements such as columns, material served form, form served purpose, purpose led to reasoning and so on.

CONCLUSION

A series of line patterns and textures was created. Those were rotated in 2D, shifted or switched, but in order to avoid a strictly ornamental result, the researchers discovered means of using texture as a structural element.

Random result Based on uncontrolled parameters (temperature, humidity, material viscosity)

Controlled results

Tool axis offset 0mm Jogging speed 0 mm/s Velocity 7mm/s

1st line of offset Base height

Random result Based on uncontrolled parameters (temperature, humidity, material viscosity)

Controlled results

Tool axis offset 0mm Jogging speed 0 mm/s Velocity 7mm/s

1st line of offset Base height

Random result Based on uncontrolled parameters (temperature, humidity, material viscosity)

Controlled results

Tool axis offset 0mm Jogging speed 0 mm/s Velocity 7mm/s 1st line of offset Base height

Z-Axis Offset 1st line of offset Tool axis offset 0mm Jogging speed 0 mm/s Velocity 7mm/s

Base height

Cantilevers and Overhangs

The cantilever studies started with the primordial shape â&#x20AC;&#x201C; the circle. After it was tested what the limits of the cantilevers a circle derived geometry can resists, the basic shape was switched, in order to test other support systems. The researchers then stared creating an actual architectural prototype, which presented openings, since light and shadow are basic architectural needs. They could safely add tunnels and arches due to previous tests and the understanding of material behavior.

Test A Test A - Simple cantilivering -Simple cantilivering - No structural support -No structural support TestTestBB - Twist cantilivering -Twist cantilivering

Test C -Complex shape for support Test C -Twist - Complexcantilivering shape for support

5º

10º 25º 15º

-Twist cantilivering 30º

20º 35º 25º 25º

40º

30º 45º

35º

40º

CONCLUSION

The issue of cantilevers and overhangs consisted in how far they can be pushed. The material was undertested in order to discover the safest way to do it, not only the most extravagant one.

Curve CuA

COLUMN STUDY

Curve CuB

25ยบ 25

While developing the aesthethics of a column, the cantilever team played with two types of curves in a series of rototranslated elements, in order to create cantilevering strategies for vertical elements.

160 mm 160mm Air Pressure: 9 bar Line Thickness: 10 mm Line height: 3 mm

Curve B Counterwise

Curve B Clockwise

Curve B Counterwise

800 mm Curve B Clockwise

Curve B Counterwise

25ยบ 25

Curve B Clockwise

Curve B

Curve A with inclination 15 15ยบ

Curve

160 mm 160mm

ERRORS

Through continous testing, the team was able to notice but also to optimize a series of errors. Some errors also have proven to have the potential to become part of the formal language, being something typical to extruding with clay, therefore something that could be taken advantage of.

CONCLUSION

The error above was caused due to the angle of cantilevering since it was too high, the underlayer couldnâ&#x20AC;&#x2122;t support the weight and collapsed. However, the texture looks constant, therefore could be used as a formal exploration. The top left photo is showcasing the errors caused by using the manual mode while using the robot, which due to instability in controlling the print is causing the material to keep extruding while the toolpath stops. While unpleasant when uncontrolled, this error could also constitute the premises of further formal exploration.

Bibliography BOOKS Minke, Gernot - Building with earth - Design and Technology of a Sustainable Architecture - ed. Neue Lehmbau-Handbuch, 2006 Winchip, Susan - Fundamentals of Lighting, ed. Bloomsbury, 2007 SCIENTIFIC PAPPERS Barnett, Eric; Gosselin, Clement - Large-Scale 3D Printing With A Cable-Suspended Robot arge-Scale 3D Printing With A CableSuspended Robot Izard, Jean-Baptiste; Dubor, Alexandre; Herve, Pierr-Ellie; Cabay, Edouard; Rodriguez, Mariola; Barrado, Mikel - Large Scale 3D printing with parallel cable robot

WEBgraphy http://additivemanufacturing.com/basics/ http://www.cais-soas.com/CAIS/Architecture/wind.htm https://iaac.net/research-projects/large-scale-3d-printing/3dprinted-bridge/ http://www.archdaily.com/419306/echoviren-smith-allen https://en.wikipedia.org/wiki/Beehive_house http://www.tecnalia.com/images/stories/microsites/robotics/ FICHA%20-%20Rob%C3%B3tica%20de%20Cables%20v30. pdf https://en.wikipedia.org/wiki/Windcatcher http://www.infoplease.com/encyclopedia/science/

Bibliography

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