Timber x Digital 1:1 Furniture Making Journal - Adaptable by Raynaldo Ali

J O U R N A L

A D A P TA B L E R AY N A L D O 7 3 9 5 7 2

A L I

ex-lab: digital furniture fabrication semester 1 - 2016 sup ervised b y Jas Jo hnsto n + Adam Mark o witz assisted b y msd Fab Lab + Wo rk sho p

J O U R N AL

CONTENTS Exploration

Furniture Development

Final Proposa l

FOLDING W E E K

1

TWIST W E E K

2

HINGE W E E K

3

JOINT W E E K

4

PIVOTING F U R N I T U R E

P R O P O S AL

1

NESTING BY LIFTING F U R N I T U R E

P R O P O S AL

2

NESTING BY SLIDING F I N AL

F U R N I T U R E

P R O P O S AL

THE TESTING N E S T I N G

B Y

S L I D I N G

P R O P O S AL

THE MAKING N E S T I N G

B Y

S L I D I N G

P R O P O S AL

WEEK 2 T W I S T

RE SEAR C H TWIST I NG T HE CONC RE TE

2

CENTRO ROBERTO GARZA SADA de ARTE ARQUITECTURE Y DISENO

TAD AO AN D O O n e of th e m asters in co nc r e te b o th a r c hi te c tur a l l y a n d stru c turally, Tadao And o , ha s p a te nte d hi s fi r s t p u blic bu ilding design in L a ti n Ame r i c a thr o ug h thi s s c h ool of art at University o f Mo nte r r e y i n Me x i c o .

1 3

O n e th in g b e came t he autho r ’ s fo c us i n thi s p r o j e c t i s th e c rea t ive m assive v o i d und e r ne a th the b ui l d i ng m a ss. S ticking to his “ritu a l ” ma te r i a l , And o e s ta bl i s h ed an uncom mon des i g n o f v o i d und e r ne a th the b u ild in g to allow m ore p er me a b i l i ty i n g r o und l e v e l .

H i s “twist” in t he void is a c hi e v e d thr o ug h i ts s ha p e .

I n fac t, what makes it m o r e i nte r e s ti ng i s the i nte r g r at i on betwee n the form and the ma te r i a l . H e a c hi e v e d t h e “twist” form b y using c o nc r e te , r e f e r r i ng to i ma g e 4.

1. T h e co n s tr u ctio n d e ta ils .

Im a ge b y d e z e e n .co m

H o wever , if we inve st igat e the v o i d i n d e ta i l s , he b r oke down the “tw isting f o r m” , whi c h s ui ts c o nc r e te p r operties, int o layers of c o nc r e te . T hr o ug h thi s l a y e ri ng tec h n ique, an elegant l o o k o f c o nc r e te twi s t i s no t i m possible, ye t re sult ing i n s o p hi s ti c a te d o utc o me .

2 . Ta ctile e xp e r ie n ce fo r m a b o v e .

Im a ge b y d e z e e n .co m 3 . Vis u a l e xp e r ie n ce fr o m u n d e r n e a th .

Im a ge b y d e z e e n .co m

T h ese “c oncre te layers” a r e b o th e x p e r i e nc e a b l e f r o m un d ern eath and ab ove, v i s ua l l y a nd ta c ti l e l y .

4. “Tw is tin g th e co n cr e te ” v o id .

Im a g e b y d e z e e n .co m

4

RE SEAR C H TWIST I NG T HE T W I ST

1

2

3

TYPICAL TWIST DEFINITION

W HAT AR E T H E ME T H O DS?

1. C onsole Mob ius b y Pierre Rena rt. Im a ge b y p ierre-rena rt. com

T h r ou gh a re search of m e r e c o nc r e te a nd wo o d mat e r ials on tw ist, aut hor found the i d e a o f twi s ti ng i s common ly lim it e d to the e x te nt o f a c e r ta i n k i nd o f “ formwork”.

2. Peeling the C oncrete.

Im a ge b y a rchda ily.com 3.. T he tw ist of concrete.

Im a ge b y eluna m i.info

T h ere is this notion of fix e d s ha p e a nd d i c ta te f o r m, w hic h au thor se e s it as a l i mi ta ti o n o f the twi s t.

T h erefor e, author se e k s to d o a fur the r r e s e a r c h a nd i nvestigation to what e xte nd “ twi s t” c a n b e d e f i ne d a s a “ twist”, both conce p tua l l y a nd p r a c ti c a l i ty .

4. T he tw ist form w ork f or p la s ter ca sting.

Im a ge b y a uthor 5. T he Pla ster Tw ist.

Im a ge b y a uthor

H o w to d rift away from t he twi s t tha t i s a s s o c i a te d w i th a fixed form?

6. C om b ina tion b etw een f orm w ork a nd p la ster.

Im a ge b y a uthor

4

5

6

RE SEAR C H TWIST I NG T HE T W I ST

1

3

2

4

AUTHOR’S DEFINITION OF TWIST

LAYERS O F S PACE

PERSPECTIVE and FUNCTIONS

Seekin g to b e m ore flexi b l e , no t l i mi te d , i t s p a r k s a ut h o r’ s th inking on how Ja p a ne s e a r c hi te c tur e i s d o ne .

T h e idea of lightne ss and f l e x i b l e i s a p p a r e nt thr o ug h t h eir ar c h itect ure. There f o r e , a utho r d e c i d e d to fur the r i nvestigate t he crux or es s e nc e o f i t.

J apan ese archit e ct ure so ug ht to uti l i s e l a y e r s o f s ho j i ( s lidin g pa p e r door), t o cr e a te d i ffe r e nt o f s p a c e s .

T h e different sp ace s also me a n d i f fe r e nt func ti o ns .

T h is c r eation of differe nt func ti o ns a r e a c hi e v ea ble th r ough t he use of the f l e x i b l e s ho j i , i t a l l o ws o ne spac e t o m e rge w it h the o the r s p a c e s a nd s ha l l e s tablish a ne w funct ion / f unc ti o ns twi s t. I n o r d e r to un d erstand the differe nt p o s s i b i l i ti e s o f the s e funct i on s, on e shall t wist the i r p e r s p e c ti v e i nto “ G o d ’ s p er spec tiv e ”, t o ove rlook i t a s a who l e p i e c e .

Auth or d efine s tw ist as a n i d e a o f b e i ng a b l e to s e e b ey on d the form , one ha s to und e r s ta nd the c o r e con c ept of it. It is the m a tte r o f ( 1) twi s ti ng o ur p e r s pec tive, the n (2) t he laye r s , s o tha t the p o te nti a l o f d i ff er en t functions can be a c hi e v e d .

1. L a ye r s o f Sp a ce s .

Im a ge b y jca s tle .in fo 2 . T h e Sh o ji. Im a ge b y jca s tle .in fo 3 . M im a H o u s in g , h o u s e o f la ye r s .

Im a ge b y m im a h o u s in g .co m 4. F le xib ility in ch a n g in g th e la ye r s .

Im a ge b y m im a h o u s in g .co m

5

6

5 -6 . T h e a b ility o f la ye r s to a ch ie v e d iffe r e n t fu n ctio n s .

Im a ge b y m im a h o u s in g .co m

EXP E R I M E NT TWIST I NG T HE PE RSP EC TI VE

VISION 1 VI S I O N 2

PE

Vision 1 = Ty p ic a l one ’ s pe r s pe ct i v e i n a s pa ce Limited vision. There is no opportunity to further twist the layers.

RS

PE

CT

IV

E

1

PE

RS

P

T EC

IV

E

2

Vision 2 = Twisted Per sp ective Alo w in g to o v e r lo o k th e p ie c e as a w h o le , e n ab lin g o n e to c o n tr o l th e lay e r s an d f u r th e r tw is t it.

EXP E R I M E NT TWIST I NG T HE PE RSP EC TI VE L AS ER

CUT

LAY ERS

EXP E R I M E NT TWIST I NG T HE F U NC TI ONS TEST 1 // SQUARE JOINT

ONE LAYER (MODULE ) OF T H E SQUAR E SH AP ED J O I NT

T H E LAY ERS W ITH C ENTRAL S QUARE P IVOT JO I N T

T W IST IN G “T H E F U N CT IO N S”

EXP ER I M E NT TW IST I NG T HE F U NC TI ONS TES T 2 // CIRCULA R JOI N T

ONE LAYER (MODULE ) OF T H E C I R C L E SH AP ED JO I NT

T H E LAY ERS W ITH C ENTRAL C IRC LE P IVOT JO I N T

T W IST IN G “T H E F U N CT IO N S”

WEEK 3 H I N G E

3D-printed + Laser Cut

T W IS T D E VE LO PM E N T TH E C HA NG EA BLE MEC HA NI SM

TEST 1 THE SQUARE JOINT fo r squ ar e-jo in t design ed lay e rs

T he j o i nt i s r e l a ti v e l y s i m pl e a n d s t ra i g h t - fo rw a rd. T h e a utho r , ho we v e r , a tte m pt e d t o n o t m e re l y re l y o n t h e fri c t i o n p r o p e r ti e s o f the j o i n t , bu t t o h a v e t w o c o m po n e n t s t h a t i s a b l e to i nte r l o c k e a ch o t h e r ( m a l e - fe m a l e ) .

T W IS T D E VE LO PM E N T TH E C HA NG EA BLE MEC HA NI SM

TEST 2 THE CIRCLE JOINT - v0 fo r cir cle-jo in t design ed laye rs

Ov e r a l l , the r e i s no s e n s e o f c o n t ro l fo r t h e c u rre n t de s i g n . T h e l a y e r s wi l l b e a b l e to m o v e a rbi t a ri l y , a l t h o u g h w h e n t h i s j o i n t me c ha ni s m i s i ns ta l l e d. H o w e v e r, t h e l a y e rs m i g h t be a bl e t o ho l d the ms e l f p ur e l y du e t o t h e pro pe rt i e s o f f ri c t i o n be t w e e n the j o i nt a nd the l a ye rs .

T W IS T D E VE LO PM E N T TH E C HA NG EA BLE ME C HANI SM

TEST 3 THE CIRCLE JOINT - v1 fo r cir cle-jo in t design ed laye rs

As a r e s ul t fr o m the pre v i o u s i t e ra t i o n , t h e l a t e s t de s i g n s e e k s to a c hi e v e a c o ntr o l l a bl e i n di v i du a l l a y e r. T h e n e w j o i n t m e c h ani s m c o ns i s ts o f two pa rt s , a s s t a t e d i n t h e be g i n n i n g . P a rt 1 ha s a f unc ti o n to ho l d a l l t h e l a y e rs t o g e t h e r, t h e n pa rt 2 a l l o w the j o i nt to l o c k the de s i re d pa t t e rn o f t h e l a y e rs .

T W IS T D E VE LO PM E N T TH E C HA NG EA BLE MEC HA NI SM

THE PO SS I BI L I TY THE CIRCLE JOINT - v1 f or c irc le -join t de s ign e d lay e rs

Pos it ive -Joint (Mal e )

P o s i t i v e - J o i nt (Ma le)

N e g a t i v e -J o i n t ( F e m a l e )

Neg a t ive-J o in t (F ema le)

POSSIBILITY 1

P O SS I B I L I TY 2

P ost -p roduc ti o n o f the v 1 c i r c l e -j o i nt, i t o pe n s u p m o re po ssib ilitie s fo r e a c h l a y e r to b e p l a c e d d i ff e re n t l y . T h e m a l e j o i n t is de signed to ho l d the who l e l a y e r s i n pl a c e . W h i l e t h e f e m a l e joint is not i ns e r te d , e a c h l a y e r c a n b e ro t a t e d a c c o rdi n g l y .

Fina l l y , the f e ma l e j o i n s ha l l l o c k a l l t h e l a y e rs .

G iven a n ex t reme po ssibilit y, ea ch la yer ca n be pla ced diffe r en t ly t o every o t h er la yer. E a ch la yer is loca t ed on e h o le di s t an ce a pa rt fro m ea ch o t h er. T h e mech a nism works t h e sa me w h ere t h e ma le join t h o lds t h e la yers in pla ce a n d t h e fema le jo in t will in t erlo ck t h e la yers a lt o g et h er.

T W IS T D E VE LO PM E N T TH E C HA NG EA BLE MEC HA NI SM 3D-printed + Laser Cut

WEEK 4 J O I N T

CNC-ed Piece C o n s u l t e d by Ra v i + Jo h n + S i a v a s h

T W IS TI NG t h e RO TAT IO N AL AXIS X/Y to Z A X I S M O D I F I C AT I O N

X / Y AXIS

Z AXI S

Appl i c at i o n t o t he pr e v i o us m o d ul e s

M O D U L E I T E R AT I O N S

1

2

3

4

Z axis MECHANISM

5

6

M e c hani s m H y po t he s i s

FURNITURE PROPOSAL1 PIVOTING I n c onjuc tion with the re s e arc h ag e nd a, author s tarted to design a furniture bas e d on the id e a of s wis s army kniv e s. This idea is inte grate d with the d e s ign of a kitc he n be nc h f or a small living apartme nt s c e nario.

2000

2400

2000

P LAN VI E W

EL EVAT IO N VIEW

1: 25

1 : 25

THE S C ENARI O KITCHEN BENCH f or a s m all liv in g ap artm e n t

E s t a bl i s h i n g a “ c h a n ga bl e ” fu rn i t u re re q u i re s a bo l d fo u n da t i o n t o w hy one w ould m a k e t he e f f ort t o c ha ng e t he f urni t ure ? .

T hr o u gh t h o ro u g h re s e a rc h e s , a pi e c e o f c h a n g e a bl e f u rn i t u re i s fa vou red in a limit ed s pa c e , bo t h v o l u m e a n d a re a w i s e .

T he a i m i s t o a l l o w o n e m a xi m i s e t h e f u rn i t u re ’ s fu n c t i o n a n d w h ile n o t bein g u sed, t h e f u rn i t u re s h a l l be m o di fi e d t o c re a t e m o re f re e spa ce.

KITCHEN BENCH v e rs ion _ 1 - ov e rall axon om e tric

pivoting joint_1

static table

pivoting joint_1

pivoting joint_2

pivoting table_1

pivoting joint_2

pivoting table_2

KITCHEN BENCH v e rs ion _ 1 - me c h an is m

maximum use

minimum use

3 tables are used static table pivot table_1 pivot table_2

2 tables are used static table pivot table_1

1 table is used static table

KITCHEN BENCH v e rs ion _ 1 - drawin gs

1600 1075 500

495

430

545 970

E .2

900 925

900

875

925

900

150

400

300

875

1570

600

250

E.1

P LAN VIEW

E LE VATI O N 1

EL EVAT IO N 2

1: 3 5

1 :35

1:35

KITCHEN BENCH v e rs ion _ 1 - join t ide a

static table leg

static table

static table leg

pivoting table_1

pivoting table_1 leg

pivoting table_2

pivoting table_2 leg

KITCHEN BENCH v e rs ion _ 2 - e xp lode d axon ome tric

static table

pivoting joint_1

pivoting table_1

pivoting joint_2

pivoting table_2

pivoting joint_3

pivoting table_3

KITCHEN BENCH v e rs ion _ 2 - ov e rall de s ign

KITCHEN BENCH v e rs ion _ 3 - ov e rall de s ign

KITCHEN BENCH v e rs ion _ 3 - drawin gs

500

1000

1500

875

750

1375 1250 1125

950 800 650 500

625

500

500

KITCHEN BENCH v e rs ion _ 4 - ov e rall de s ign

KITCHEN BENCH v e rs ion _ 4 - drawin gs

400

300

350

400

400

750

300

350

300

600

600

400

FURNITURE PROPOSAL2 NESTING by LIFTING Af te r the rotational axis motion, author d e c id e d to fur ther exp lor e othe r pos s ibilitie s of motion to ac hie v e a be tte r m echanism.

This time author atte mpte d to c re ate an ad aptable coffee tab le with ne s te d s tools - L I F TI NG motion

R E M O VA B L E C O M P O N E N T INITIAL TESTING

C O M PA C T C O N F I G U R AT I O N

D I S A SS E M B L E D C O N F I G U R AT I O N

COFFEE TABLE + STOOLS v e rs ion _ 1 - ov e rall de s ign

COFFEE TABLE + STOOLS v e rs ion _ 1 - drawin gs

900 450

900

450 175

625

450 200

200

COFFEE TABLE + STOOLS v e rs ion _ 1 - with ou t tab le

COFFEE TABLE + STOOLS v e rs ion _ 1 - du p lic ate d modu le s

COFFEE TABLE + STOOLS v e rs ion _ 2 - drawin gs

900 450 350

400 175

450

625

200

COFFEE TABLE + STOOLS v e rs ion _ 2 + v e rs ion _ 3 - c omp aris on

W I T H O U T S T O R A G E S PA C E

stools are removeable

W I T H S T O R A G E S PA C E

stools are removeable

support and table are fixed support and table are fixed

COFFEE TABLE + STOOLS v e rs ion _ 3 - drawin gs

900 450 350

400 175

450

625

200

AUTHOR CREATED 1 TO 1 PROTOTYPE TO TEST THE LIFTING MECHANISM USING CARDBOARD, HOWEVER, THE PROTOTYPE GOT DISCARDED BEFORE DOCUMENTED.

COFFEE TABLE + STOOLS v e rs ion _ 3 - with tab le + s torage s p ac e

COFFEE TABLE + STOOLS v e rs ion _ 4 - ov e rall de s ign

stools are removeable

TESTING DIFFERENT SHAPE o ver all design support and table are fixed

COFFEE TABLE + STOOLS v e rs ion _ 4 - drawin gs

900 450 350 200

400 175

450

625

0 30

FINAL FURNITURE PROPOSAL NESTING by SLIDING The pre v ious id e a of ne s ting by lifting is que s tione d r egar ding its lifting me c hanis m. I t s e e ms the lif ting motion is not the b est r esolution of un-ne s ting the s tools . The re fore , for the f inal p r op osal, author introd uc e d a S L I D I NG me c hanis m.

COFFEE TABLE + STOOLS ite ration s

COFFEE TABLE + STOOLS de v e lop m e n t

COFFEE TABLE + STOOLS S tool’s Ae s th e tic D e v e lop me n t

T h e id e a is to cre a te a con tra s t b e tw e e n th e e xte rn a l fa ce s a n d i nt e r nal fa ce s . Wh e n u n -u s e d , th e s tool w ill b e n e s te d on to th e ta b le , thus t he in te n tion is to h a v e a s e a m le s s a e s th e tic of n a tu ra l b irch a lon g w i t h t he ta b le . T h e n , on e will d is cov e r a con tra s t colour ( re : im p re s s ion ) w he n th e y d e -n e s t th e s tool from th e ta b le .

C on s u lte d b y Adam Markowitz + J as J oh n s ton

iter atio n 1 RED

ite ration 2 BIRCH

iter atio n 5 G REEN

ite ration 6 G R AY

iteration 3 Y E L LO W

iteration 4 W H I TE

ch o s e n co l o u r B L AC K

COFFEE TABLE + STOOLS f in al m ate riality p ale tte T h e ov e rall mate riality p ale tte is c on s u lte d b y Adam Markowitz + J as J oh n s ton

F.1 18mm birc h plywood - MaxiPly finished with double c oat of O smo Po ly x O il R aw - Co lo r e x c onsulted with Mark from Colorex + Adam M ar k o w itz

F.2 18mm birc h plywood - MaxiPly finished with British Paint semi-gloss e n am e l b lac k p ain t - B u n n in gs c onsulted with Bunnings’ Paint Shop Sale s + Adam M ar k o w itz

F.3 Tasmanian O ak Dowel - Bunnings finished with double c oat of O smo Po ly x O il R aw - Co lo r e x c onsulted with Mark from Colorex + Adam M ar k o w itz

F.4 Jarrah Wedge - Sc rap from MSD’s Wo r k s h o p finished with double c oat of O smo Po ly x O il R aw - Co lo r e x c onsulted with Mark from Colorex + Adam M ar k o w itz

COFFEE TABLE + STOOLS e xp lode d axon om e tric

table top F.1

the nest F.1

table legs F.1

COFFEE TABLE + STOOLS th e c on f igu ration

N ested Mode

COFFEE TABLE + STOOLS th e c on f igu ration

E xpanded Mode

COFFEE TABLE + STOOLS s tool e xp lode d axon om e tric

stool top F.1

mitre corner joint

inside faces F.2

dowel F.3

wedge joint F.4

THE TESTING NESTING by SLIDING

Prior to making the final pie c e , it is c ruc ial to te s t the featur ed/ mos t promine nt d e tails : s lid ing me c hanis m, mite r joint, and dowel we d g e joint.

Test ing t he SLIDING ME CHANISM Before making the final pieces, there are several testings required in order to prove the design will eventually work.

The first test is the sliding mechanism. Author created 1 to 1 stool’s prototype using available 18mm scrap plywood with screw fixings.

Consulted by Ross Berryman

FL

Sawstop Tab le Saw

Milwa u ke e Co rd le s s Tool

D rill Bit

C ou n te rs in k D riv e r Bit

S q uar e Driver Bit

ING O AT

F l at he ad S q uar e Screw

S - NE

TED

Te s t i ng t he M I T R E J O I N T Another crucial details in my furniture piece is its joints.

All of the stool’s planes will be joined using miter technique, with domino pieces. Prior making the final, it is important to investigate the machine’s capability to create a perfect 45 degree angle cut.

Consulted by Jas Johnston + Adam Markowitz + Ross Berryman

S a w s top Ta b le S a w

Ma ggi Ta b le S a w

F e s tool D omin o D rill

D o m i no B i s c ui t s

Te s t i ng t he D ow e l W e d g e J oi nt One of the most featured details in my furniture piece is the dowel joint. With only woodwork, the dowel will be fixed to the plywood.

Consulted by Adam Markowitz + Jas Johnston

Lathed + Band Sawed Dowel // Drilled Plywood

Sa ws to p Ta bl e Saw

Mag g i Tab le Saw

Wood La th e

Tria n gle /P yra m id La th e C h is e l

D rill B e nc h P r e s s

B and S aw

D o v e t ai l S aw

Lathe-ing Process Consulted by Adam Markowitz

THE MAKING NESTING by SLIDING

“S tep by S tep” in making the final pie c e.

Reflectio n: Po st-mak ing the final p iece, it is arguab le that the sto o ls mitre cut, h o le o n s to o l’ s to p as well as the fillet co rner can b e do ne in CN C. H o wever, I intentio n a lly b a la n ce d my p ro cess b etween CN C, the tab le, and manual wo o dwo rk , th e s to o ls .

I have learnt b o th digital and manual realm fro m this ap p ro ach. I u n d e r s ta n d h o w the CN C wo rk s and mo re imp o rtantly ho w it is do ne manually. T he r e fo r e , I fu lly understand the mak ing p ro cess o f o ne furniture. I have learnt a lo t fr o m th e m a n u a l wo o d-mak ing p ro cess and grateful I decided to tak e this ap p ro ach, w h ich w ill b e v e r y useful fo r my future endeavo ur.

The Making Process The Table 1

Preparing the CNC file

2

3

Chisel the round corners

Sand the surfaces for finish ready

4

5

6

Assemble the legs and nest

Apply finish to the legs, nest, and table top

Assemble the table top and sand to finish

Osmo Polyx Oil Raw

400 grit - 800 grit

The Stool

1

Cut the plywood into the designed measurement

2

Cut mitre 45° angle

12

11

Apply glue on the edges and dominos joint

Join 2 stool’s top with the lathed dowel

24mm domino biscuits

13

Mallet the wedge into the dowel’s notch wedges are cut using band-saw

3

Mark every miter joint edges

10

4

5

6

Drill the dominos hole

Fillet the corner detail on stool’s top

Drill holes on the stool’s top for the dowel joint

with festool domino 500

with plunge router

9

8

7

Prepare the dowel

Paint the internal faces

Masking every planes’ edges for paint-ready

Sand the internal faces of stool for paint-ready

lathe process

British Paint black semi-gloss enamel paint

240 grit

14

15

16

17

18

Clamp the stool

Cut the excessive dowel + wedge

Sand the outer faces of the stool for finish ready

Apply the finish product

Sand the surfaces to finish

with dovetail saw

240 grit

Osmo Polyx Oil Raw

400 grit - 800 grit

t he fina le

t he Nest

d e-nest t he St ool

t he Applica t ion

remova ble Ta ble Top

Sha d ow Line La ng ua g e Det a ils

Sha d ow Ga p

E d g e Mit re J oint

T he Nest Det a il

t he Nest w it h it s St ools

Ta ble Top Cross Det a ils

Dow el J oint Det a ils (E x t erna l a nd Int erna l)

Dow el J oint Det a ils (Int erna l)

Perfect Mit re Corner J oint

Dow el W ed g e J oint (Birch - Ta sma nia n O a k - J a rra h)