The Funnel

PART B

‘The Funnel’ Design Contest for a Freeform Pavilion with Additive Manufacturing

Date Course Subject Students

16.04.2021 Technoledge Facade Design (AR0134) Design of Pavilion overlooking the Timmerhuis, Rotterdam 54xxxxx | Randy Bongers 5315883 | Rhea Ishani 5319110 | Pragya Chauhan 4568752 | Pim Brueren

1. Introduction 1.

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Background Information Location Problem Statement Research Question

1.1 | Background Information

Design Competition Brief: 1.

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Develop a design at two scales: a. Overall Scale (freeform enclosure) b. Detailed Scale (including node design) The design concept should be present at both these scales. Your design should consider the different aspects of quality façade construction a. Performance b. Cost c. Assembly Make use of Additive Manufacturing for your node solution using the metal AM technology of your choice (SLM or WAAM)

Design Boundary Conditions: 1.

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Use of Jansen VISS system as base system .

Max 35 degree deviation between faces (positive or negative).

5m(l) x 5m(w) x 4m(h) bounding box.

Glazing Planar or within limits of coldbending.

Maximum 100 Interior Nodes (excluding edge nodes).

Structurally Free-standing structure.

1.2 | Location Timmerhuis, Rotterdam Architects Year of Completion Built Area Total floors Maximum height

- OMA - 2015 - 45,000 m² - 20 - 63m

Timmerhuis is a Mixed Use building, with Offices, Residential, Parking, Retail, a Museum and a Gallery

1.3 | Problem Statement 1.

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Timmerhuis looks like an office building Monotonous buildings on the surroundings The building opens to the road directly, has a very abrupt entrance The landscape of the plaza is not very interactive and engaging

1.4 | Research Question

How can architecture enhance the engagement for the plaza overlooking the Timmerhuis by optimizing geometry and circulation?

2. Early Concepts 1.

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Design 1 Design 2 Design 3 Design 4

2.1 | Variant 1

Design based on a deconfigured terras umbrella. The structure of an umbrella used as inspiration for a self standing structure made out of the VISS system.

2.2 | Variant 2

Dome design made out of triangular panels and with entries on multiple sides.

2.3 | Variant 3

Dome design with curved beams, each beam is connected at the top by the pressure ring.

2.4 | Variant 4

Glass cantilever design , made out of triangular glass panels..

3. Design Development 1.

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Vision Concept Developing the Concept

3.1 | Design Vision

Extension to the BrewDog brewery

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Encourage interaction

Protection from bad weather conditions

Contrasting the form of the Timmerhuis by using triangles Interactive lighting

Enhance circulation

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Different appearance during the day and night

Semi Open Pavilion Guides the movement through the space

3.2 | Concept

OUTSIDE

INSIDE

The main concept theme is a funnel, the building shape should guide people through the space and within the building.

3.3 | Developing the Concept

Sketches were made to illustrate ideas of incorporating the funnel concept into design variant 2.

Such as carving walls to guide people in , deconstructivist/fragmenting of the design,showing the funnel flow in decreasing panel sizing and changing the size and shape of the paviljon entrances to attract more attention to them.

The idea of carving walls to guide people to the entrance was taken into the design, the walls should still consist out of the triangular panels. However, in smaller size to show the flow of the funnel concept in the building as well.

3.3 | Developing the Concept

To get the right shape for the funnel concept, some experiments were done on the shape and volume of the building in the program Rhino.

These are some of the options that were developed

3.3 | Developing the Concept

We finalized an egg shaped dome-like structure which was asymmetric. The pavilion is semi open and is therefore not entirely closed. The openings are facing the entrance to the building and two into the plaza. This is to enhance the circulation - the pavilion guides the movement through the space, and creates an ambience.

4. Architecture Design 1.

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Function & Appearance Analysis (Wind, Radiation) Optimizing the Geometry The Final form

4.1 | Function & Appearance Functions During the day, the pavilion can act as a shelter, a lunch area for the office goers and an experiential space. While during the night, the pavilion acts as an entry to the bar. It will be attraction point with standing tables an a dancing area with music and lighting.

Appearance The pavilion is also designed to change appearance by becoming darker and more transparent depending on the sunlight. This is done using photochromic film.

For the VISS panel infill , double glazing assembly with minimum thickness possible was chosen. This was done for integrating the photovoltaic cells and the photochromic film within the glazing.

Photovoltaic cells will be incorporated in the panels where there is a high radiation load.

Photochromic film will be applied throughout the whole paviljon, to decrease the amount of glare inside.

When exposed to the sun’s UV light. The photochromic film molecules react to create a protective darkening effect or tint. The molecules react by changing their shape/structure to absorb the light when exposed to the UV light radiation.

The film darkens or tints fast within 10 minutes. Cutting the glare by up to 85% and reduce the UV Light by 99.5%. The film is supplied on a roll of 1520mm x 30m, minimum 5m long roll per order.

4.2 | Analysis of Wind and Sun Radiation Wind As per the analysis, the West direction has significantly high wind speed, hence we have provided a closed facade to the pavilion on that side. The North and East of the pavilion receive less winds, hence the openings have been provided there.

Sun Radiation As per the analysis, the South side receives the most amount of sunlight but it is shaded due to the large mass of Timmerhuis. The next highest radiation is received on the West side, which we have identified as an ideal location to place the photovoltaic panels.

4.3 | Optimizing the Geometry To optimise the structure further and integrate the design to accommodate the VISS System, we tried to solve the geometry through computation analysis.

The first direction we took was using the Kangaroo plugin. We were not able to dwell into the Plugin and seek better results as it was an unfamiliar plugin. The design was optimised further by introducing a concept of triangulating the mesh using Lunch box.

The process of design is explained in the Flowchart

4.3 | Optimizing the Geometry

After we arrived at a desirable form. The next step was to optimise the number of Nodes and to do, we incorporated Lia’s Script

4.4 | The Final Form

Top view of the Pavilion

4.4 | The Final Form

5. Detail Design 1.

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VISS profiles Lighting Design Design of the Node Overall Scheme of the Node Assembly sequence Manufacturing Process 3D printing Glazing Risk analysis

IN

5.1 | VISS Profiles For the paviljon, the VISS profile with the size 50mm x 50 mm Is chosen. This was the smallest size in the catalog, due to the fact the loads on the structure were relatively low.

For the lighting we integrated the LED lighting into a cap which is connected to the profile. The cap was added instead of changing the profile shape since we discussed with the advisor from Jansen, that changing an exciting profile would not be economically achievable.

Therefore if we wanted to add integrated lighting to the viss system as an extra to the system, another profile is needed. We chose therefore the smallest 50 wide profile they make.

These very three components are then welded together in the factory, the assembly would be finished with two VISS system profiles and two end plates for connecting the node.

OUT

5.2 | Lighting design

Plastic LED 50 x 18 mm Profile

The main concept theme is funnel, the building shape should guide people through the space and within the building. Where the principle of a led strip profile is used, and can possibly an existing plastic cover be used.

5.3 | Design of the Node

Week 1 reference

Week 2 designing a symmetrical web within the hexagonal node

Week 3 changing angles as per the panelization, making web more solid

Week 4 making stronger connections

The idea was to implement the concept of a funnel in design of the node. This way we could carry the same concept from the large scale (overall design) to reflect also in the design of details.

This helped understand the freedom that AM offered in the design of geometry while also taking note of the limitations and careful selection of the process of manufacturing.

The series of pictures show the evolution of Node through the design weeks as a result of research and design development.

Through the weeks we got introduced to various concepts of node design that integrates additive manufacturing.

In the final design of the node, the node is connected by screwing bolt into the cover plate of the preassembled VISS profiles. Their are mad bigger gaps to ensure tightening is made possible. Also there is a pipe gateway for the electronics of the LED provided in the underside of the node.

5.3 | Design of the Node

5.4 | Overall Scheme of the Node 2 1

reduction in total mass of node

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2 load condition 1

Due to the asymmetrical shape of the dome and reduction in size of the glass panels from bottom to top.

Glass panels much larger in the bottom with nodes spaced 1.8 meters apart, while at the top, the glass panels are smaller, with nodes spaced .4 meters apart. (approximate values)

load condition 2

The node should ensure the watertightness, strength and structural stability, and connect well to the VISS system.

load condition 3

5.5 | Connections

All the different component that are needed for the assembly of the pavilion.

The most critical parts are the structural parts; the node, viss system and connection bolt and plates. And the water drainage, is also an important aspect for a water/air tight pavilion. So different kind of silicons with different cover plates are used to ensure that no water will enter the inside of the pavilion.

For the water drainage we use the Multi-layer: cut & glue approach. This example was provided by lia in her presentation slides on possibly connections. Because our pavilion has nearly vertical lines to the base of the pavilion that is why we propose this approach.

5.5 | Assembly sequence

5.6 | Manufacturing Process We propose that 3 parts are produced by means of additive manufacturing. This ensures that there is more freedom of movement in the node and also in the characteristics of the remaining parts.

The node provides power transmission and structural strengths of the pavilion, the top plate ensures that the silicone water lines can do their job so that the pavilion is water and air tight. The cover cap is therefore unique for each node and can also differ in curvature to reinforce this differentiation. The rest can be mass produced to speed up the process and save costs.

additive manufactured

mass produced

5.6 | Manufacturing Process The node is of a small size, biggest size of 200x200. So we propose to use the WAAM method, as this is way quicker and cost efficient.

However we would like to use the 6 axis printing technique as seen in the right beneath corner, to increase overhang capability.

The WAAM method is less precise then the SLM technique, but as the node is a very solid and rough geometry, the amount of detail that SLM provides isn’t used.

As proposed we are using 3 different elements to be additive manufactured. Each element should be done separately.

The infill of the node could be later adjusted as the strength of the node may vary over the pavilion. Hereby an structural analyst kan look whenever necessary and how much or in which direction.

Criteria

Selective Laser Melting

Wire and Arc Additive Manufacturing

Precision while printing

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Machining / Finishing after printing

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Cost

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Time

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5.7 | 3D printing

The ultimate test for an object which has to be additive manufactured, is to check it in real life. Having an in house 3D printer - an FDM printer, that was a straightforward process. The node is printed at 66% size instead of the 100% scale. This is done to save time and material costs.

The 3D printed object shows that the geometry we made in Rhino is not just "digitally visually correct" but can actually be built. The shapes speak more for themselves in real life than on a computer screen.

A 20% infill was used because FDM printers can do some bridging but prefer to put their plastic lines on a layer that is below. For additive fabrication, the node infill could differentiate by how much forces the node should address.

However, improvements can be made based on the cavity hole cutouts as they don't disappear seamlessly into the rest of the node.

5.8 | Glazing For the VISS panel infill, double glazing assembly with minimum thickness possible was chosen.

This was done for integrating the photovoltaic cells and the photochromic film within the glazing.

5.9 | Risk Analysis In the table certain risks situation are analysed.

The risk factor is calculated by the following formula : RD = WS x BS x ES The values are acquired by using the ABT risk analysis table.

When the risk factor is below 70, no safety measures need to be taken.

When the risk factor is above 70 preventions, safety measures need to be taken.

6. Summary 1.

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Further Improvements Reflection on the course

6.1 | Further Improvements 1.

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Make the node lighter and optimize it to use less material Integrate the lighting within the node, right now it is only in the VISS system.

Designing the top node, which has many profiles coming together.

Improve the drainage in the node.

Could have developed a more interesting form for the structure.

We overlooked a couple of practical aspects to enforce our architectural concept.

Design and printing can be optimized by making toolpaths using software applications like RoboDK.

6.2 | Reflection for the Course 1.

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Designing online is very challenging!

Cross-group interaction would be helpful.

In an online learning environment, the diverse comments received from the tutors was challenge to process and incorporate further.

Comments during the online crit were sometimes confusing.

It was nice to receive positive and encouraging words after the final session.