Workshop AADRL

ADAPTIVE MANIFOLD ASSEMBLAGES Omar Kaddoura, Taeyoon Kim, Ogulcan Sulucay, Nicholas Rawitscher.

Tyson Hosmer AADRL 2017

Introduction

The goal of the workshop aims to construct an abstract architectural space that is continuous, topologically and materially complex yet can be explicitly 3D-modelled through simple procedures. This continuous architectural space will be broken down into a set of simple parts which will be studied as a reconfigurable assembly system. Teams will develop an analog coding language to describe recursive sequences of assembly that yield radically differentiated behaviours across field conditions to achieve an adaptable architectural language. Designs will address part-to-whole relationships along with variations in material andformal order over a continuous yet diverse range of scales in order to define a complex notion of space only achievable through contemporary digital design and fabrication methods. The project will be developed in parallel as a scalemodel, 3D-printed assemblage that considers fabrication constraints as opportunities to introduce visual qualities within the design, becoming intrinsic to a designed formal, spatial and material expression.

TABLE OF CONTENTS CHAPTER I : MODELING EXPERIMENTS CHAPTER II : MINIMAL SURFACE CHAPTER III : PROTOTYPES & JOINTS CHAPTER IV : FINAL MODEL CHAPTER V : RECONFIGURABLE PARTS

Design Methodology The workshop will undertake a design research into spatial, formal and material expression through 3D-modelling and 3D-printing. Topologically complex polygon meshes will be developed using simple procedural operations developed through design catalogues.

These procedures will investigate topological mesh modelling, rind modelling and strategise the role of manifold topologies to define architectural space. These formally complex models must be also developed as closed manifold meshes suitable for 3D-printing. Designs will aim to explore the limits of high-resolution fabrication, modelling and the use of texturing within 3D-virtual spaces and 2D-rendered visualisations. The workshop will operate through a continuous and iterative prototyping proceduresess

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CHAPTER I : MODELING EXPERIMENTS

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1.0 Modeling Experiments

GEOMETRIC CATALOGUE

2D

Square Plane

Pyramid

Geometry

Cube

3D

Dodecahedron

Helix

DIMENSION

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PRIMITIVE

EXTRUDE/BEVEL/PULL

BRIDGE/SCALE

MODULE

GEOMETRY

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1.0 Modeling Experiments

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01. CREATE PLANE

02. EXTRUDE, TWEAK

01. CREATE CUBE

02. SUBDIVIDE FACES

03. MIRROR, MERGE

04. MERGE VERTICES, TWEAK

03. EXTRUDE FACES

04. TWEAK VERTICES

05. DELETE FACES, EXTRUDE EDGES

06. MERGE, TWEAK

05. TWEAK EDGES

06. MIRROR, COMBINE, BRIDGE, MERGE

07. DELETE FACES, EXTRUDE, EDGES

08. EXTRUDE, MERGE, TWEAK, BRIDGE

07. SQUASH, TWEAK

08. TWEAK

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1.0 Modeling Experiments

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01. CREATE DODECAHEDRON

02. EXTRUDE FACES

01. CREATE PYRAMID

02. BEVEL

03. BEVEL

04. TWEAK EDGES

03. DELETE FACES, BRIDGE

04. MIRROR, COMBINE, BRIDGE, MERGE

05. MIRROR, COMBINE, BRIDGE, MERGE

06. MIRROR, COMBINE, BRIDGE,

05. MIRROR CUT, COMBINE, MERGE

06. MIRROR CUT, COMBINE, MERGE

07. SQUASH

08. MIRROR, COMBINE, BRIDGE, MERGE

07. SQUASH

08. TWIST, TWEAK, SCALE 2D

MERGE

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1.0 Modeling Experiments

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01. CREATE HELIX

02. MIRROR

01. CREATE CUBE

02. EXTRUDE

03. DELETE FACES

04. BRIDGE FACES

03. TWEAK

04.INSERT EDGE LOOP

05. INSERT EDGE LOOP

06. TWEAK EDGES

05. DUPLICATE

06. BRIDGE

07. EXTRUDE FACES

08. BRIDGE FACES

07. DUPLICATE SPECIAL, ARRAY

08.SQUASH

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1.1Prototyping

IINITIAL PROTOTYPING STUDIES

Failed prototype, low thickness, easy to clean

skeletal structure, hard to cleaning

Experiment with printing speed and quality, easy to clean

Nested skeletal structure, hard to clean

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Overlaping structure, medium resoltuion print

Nested skeletal structure, hard to clean

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CHAPTER II : MINIMAL SURFACES

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2.0 Minimal Surfaces

CATENOID is a minimal surface arising by rotating a catenary curve around an XY plane founded by Leonhard Euler in 1744

BATWING is a type of the Schoen minimal surfaces which originated from tetrahedron .

SCHWARZ minimal surface is a periodic minimal surfaces founded

by Hermann Schwarz in 1865.

MINIMAL SURFACE EXPERIMENT: The purpose of the following experiment is to explore the toplogical aspects for some types of the minimal surfaces through polygon mesh modeling techniques. Using Autodesk Maya software, we try to demonstrate the potentials of predefined object, as well as the possibilities of evolving the minimal surfaces.

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SCHOEN minimal surface is originally founded by Alan Schoen in 1970 who came up with 12 new Triple periodic minimal surfaces based on skeleton graphs and spanning crystallographic cells.

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2.0 Minimal Surfaces

CATENOID MINIMAL SURFACE

TOP VIEW

SIDE VIEW

3D VIEW

PROCESS

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01. CREATE PLANE

02. EXTRUDE, SCALE EDGE

03. DUPLICATE, ROTATE

04. DUPLICATE, MOVE, BRIDGE

05. BRIDGE

06. BRIDGE

07. BRIDGE

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2.0 Minimal Surfaces

BATWING MINIMAL SURFACE

TOP VIEW

SIDE VIEW

3D VIEW

PROCESS

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01. CREATE CUBE

02. DELETE 3 FACES, EXTRUDE 4 EDGES

03. MIRROR X,Y AXIS, MERGE VERTICES

04. BEVEL EDGES, MERGE VERTICES

05. MIRROR X,Y AXIS, MERGE VERTICES

06. MIRROR X,Z AXIS, MERGE VERTICES

07. MIRROR X,Z AXIS, MERGE VERTICES

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2.0 Minimal Surfaces

BATWING MINIMAL SURFACE

TOP VIEW

SIDE VIEW

3D VIEW

PROCESS

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01. CREATE CUBE

02. DELETE 3 FACES, EXTRUDE 4 EDGES

03. BEVEL EDGES

04. MIRROR X AXIS, DELETE 2 FACES, MERGE

05. MIRROR X,Z AXIS, MERGE, BRIDGE, EXTRUDE

06. EXTRUDE NAKED EDGES

07. EXTRUDE NAKED EDGES BRIDGE

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CHAPTER III : PROTOTYPES & JOINTS

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3.0 PROTOTYPES & JOINTS

PROTOTYPE STUDIES

Shoen minimal surface

Shwarz minimal surface

Variation of batwing minimal surface

Variation of final model

Shoen minimal surface

Shwarz minimal surface, based on Batwin

Test print study of final model

First prototype of some final model components

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3.0 PROTOTYPES & JOINTS

JOINT STUDIES

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JOINT A

JOINT B

JOINT C

JOINT D

PROS

PROS

PROS

PROS

- Strong & Secure connection - Strong against shear force and lateral force

- Strongest connection - Strong against shear force, compression and tension

- Slender & requires small volume - Strong against lateral force and compression

- Simple & applicable to many different situations - Strong against tension & compression

CONS

CONS

CONS

CONS

- Large section area - Connection volume

- Exposed to diagonal lateral force - No locking mechanism

- Large section area

- Loose connection - Locking mechanism requires extra thickness 31

3.0 PROTOTYPES & JOINTS

JOINT STUDIES

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JOINT E

JOINT X

JOINT Y

PROS

PROS

PROS

- Strong against axial compression and tension - Provides flexibility

- Extremely strong & secure connection

- Simple & easy to assemble - Strong against compression & tension

CONS

CONS

CONS

- Loose connection - Allows reconfiguration - Weak against lateral force and shear force - Requires volume and cavity

- Difficult to assemble - Difficult to apply to curvature due to thickness

- Weak against shear force - Introduces extra pattern

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CHAPTER IV : FINAL MODEL

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4.0 FINAL MODEL

DESIGN PROCESS

TOP VIEW

SIDE VIEW

3D VIEW

PROCESS

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01. CREATE PLANE

02. EXTRUDE, DELETE FACES

03. MIRROR Y AXIS

04. MIRROR Z AXIS

05. EXRUDE EDGES, TWEAK VERTICES

06. TWEAK VERTICES

07. EXTRUDE EDGES, BRIDGE, TWEAK

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DESIGN PROCESS

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4.0 FINAL MODEL

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4.0 FINAL MODEL

COMPONENT TYPES

Joint B4 - Connect Comp E

Joint B3 - Connect Comp E

01. A-COMPONENT/ 12 TIMES

02. B-COMPONENT/ 12 TIMES

Joint B2 - Connect Comp E

03. C-COMPONENT/ 6 TIMES

04. D-COMPONENT/ 3 TIMES

Joint D - Connect Comp A & B&C

Joint B1 - Connect Comp G&F

05. E-COMPONENT/ 6 TIMES

06. F-COMPONENT/ 6 TIMES Joint Y - Connect Comp A&F

07. G-COMPONENT/ 3 TIMES

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08. H-COMPONENT/ 22 CUSTOMIZED

The Final Model has 93 joints in three different types applied in 5 different ways in terms of scale and angle.

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4.0 FINAL MODEL

JOINTS APPLICATION

Joint Y - Connect Comp A&F

Joint B3 - Connect Comp E

Joint D - Connect Comp A&B&C

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Joint B2 - Connect Comp E

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4.0 FINAL MODEL

JOINTS APPLICATION

Joint D - Connect Comp A&B&C

Joint D - Connect Comp D&E

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COMPONENT TYPES

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Type E

Type G

Type H

Ultimaker 2.0

Ultimaker 2.0

Ultimaker 2.0

2.0 mm

2.0 mm

2.0 mm

2.0 mm

Infill density

25%

25%

25%

25%

60 mm/s

Print speed

60 mm/s

60 mm/s

60 mm/s

60 mm/s

120 mm/s

120 mm/s

Travel speed

120 mm/s

120 mm/s

120 mm/s

120 mm/s

Everywhere

Everywhere

Everywhere

Support placement

Everywhere

Everywhere

Everywhere

Everywhere

15%

15%

15%

15%

Support density

15%

15%

15%

15%

Dimensions

99.5 X 59.4 X 68.8 mm

80.5 X 115.1 X 62.2 X 67.0 X 105.0 mm 74.1mm

53.6 X 42.6 X 49.8 mm

Dimensions

136.0 X 104.2 X 106.2 mm

132.4 X 45.8 X 73.5 X 169.5 X 53.6 X 42.6 X 103.5 mm 55.0 mm 49.8 mm

Material type

PLA

PLA

PLA

PLA

Material type

PLA

PLA

PLA

PLA

Number of pieces

12

16

6

3

Number of pieces

6

6

3

6

Total material use

34.08 m

47.07 m

24.06 m

4.71 m

Total material use

44.04 m

47.58 m

12.03 m

27.06 m

Total printing time

30 hours

36 h 8 min

7 h 68 min

3 h 9 min

Total printing time

26 h 34 min

36 h 48 min

7 hours

20 h 94 min

Type A

Type B

Type C

Type D

Printer type

Ultimaker 2.0

Ultimaker 2.0

Ultimaker 2.0

Ultimaker 2.0

Printer type

Ultimaker 2.0

Layer height

2.0 mm

2.0 mm

2.0 mm

2.0 mm

Layer height

Infill density

25%

25%

25%

25%

Print speed

60 mm/s

60 mm/s

60 mm/s

Travel speed

120 mm/s

120 mm/s

Support placement

Everywhere

Support density

Type F

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4.0 FINAL MODEL

PRINTER VOLUME

255 X 280 X 287 mm

223 X 205X 287 mm

223 X 205X 152 mm

223 X 205X 287 mm

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463.0 X 423 X 160 mm

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4.0 FINAL MODEL

PRINTED FINAL PARTS

Component type C

Component type B

Component type F

Component type A

Component type B

SComponent type D

Component type E

Component type G

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OVERALL ASSEMBLY LAYOUT

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4.0 FINAL MODEL

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MODEL PICTURES

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4.0 FINAL MODEL

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CHAPTER V : RECONFIGURABLE PARTS

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5.0 Reconfigurable parts

BODY PLANS

2D single closed cell growth

Component Iteration 01

iteration 03

Batwing Mnimal surface

2D loop growth Iteration 01

Iteration 03

Iteration 05

2D linear growth Iteration 01

Iteration 03

Iteration 06

2D open cell growth Iteration 01

Component B

Iteration 04

Iteration 10

3D open cell growth Iteration 04

Iteration 08

Iteration 15

3D closed cell growth Iteration 01

Iteration 08

Iteration 12

2D Closed cell growth Iteration 03

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Iteration 06

Iteration 10

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5.0 Reconfigurable parts

SYNTAX

CA.M

CB.F.01

CA.F

CB.M.01

CB.M.02

Syntax CB.F.02

Rotate = Rot Orientation plane = {o}

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Connection vector = Con.Vec

Component B = CB

Random interval = Ran

Male Joint 01 = CB.M.01

Component A = CA

Male Joint 02 = CB.M.02

Male Joint = CA.M

Female Joint 01 = CB.F.01

Female Joint = CA.F

Female Joint 02 = CB.F.02

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5.0 Reconfigurable parts

RECONFIGURABLE PARTS

CA

CA

CA

2D closed loop

2D linear growth

2D loop growth

(Ran ->CA.M or CA.F) -> {o} ->Con.Vec -> {o} -> (C.A.F or CA.M) -> (Rot 90)

(Ran ->CA.M or CA.F) -> {o} ->Con.Vec -> {o} -> (C.A.F or CA.M) -> (Rot Ran 90 or 180)

Itearations: 03

Itearations: 08

(Ran ->CA.M or CA.F) -> {o} -> Con.Vec -> {o} -> (C.A.F) -> (Rot 90) (CA.F) -> {o} -> Con.Vec -> {o} -> (C.A.M) -> (Rot 180)

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Iterations: 07

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5.0 Reconfigurable parts

RECONFIGURABLE STUDY

CA

CA + CB

CA + CB

2D open cell growth

3D open cell growth

2D loop growth

(CA.M) -> {o} -> Con.Vec -> {o} -> (C.A.F) -> (Rot 90) (CA.F) -> {o} -> Con.Vec -> {o} -> (C.A.M) -> (Rot 180) Itearations: 16

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(Ran -> CA.M or CA.F) -> {o} ->*Con.Vec -> {o} -> (C.A.F or CA.M) -> (Rot Ran 90 or 180) Itearations: 24

( Ran ->CB.M.01 or CB.F.01 or CB..M.02 or CAB.F.02) -> {o} ->*Con.Vec -> {o} -> (C.B.F.02 or CA.M) -> ( Rot 90 or 180) Itearations: 20

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5.0 Reconfigurable parts

RECONFIGURABLE STUDY

CA + CB

CA + CB

CA + CB

2D open cell growth

3D open cell growth

3D open cell growth

(Ran ->CB.F.01 or CB.M.01) -> {o} -> Con.Vec -> {o} -> (C.B.M.02 or CA.F) -> (Rot 90 or 180 )

(Ran -> CB.M.01 or CB.F.01 or CB..M.02 or CAB.F.02) -> {o} ->*Con.Vec -> {o} -> (C.A.M or CA.F or C.A.M or CB.M.02) -> ( Rot 90 or 180)

(Ran -> CB.M.01 or CB.F.01 or CAB.F.02) -> {o} ->*Con.Vec -> {o} -> (Ran ->C.A.M or CA.F or C.B.M.01 or CB.M.02 or CA.M or CA.F) -> ( Rot 90 or 180)

Itearations: 10

Itearations: 24

Itearations: 24

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