Photoceramics| Bucky Lab Report | Building Technology

TU Delft | 2020 | Building Technology

PHOTOCERAMICS Group IV

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Profiles //

Juan Sebastian Project manager

Stella Pavlidou

Communication manager

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Jens Slagter

Project manager

Rhea Ishani

Workflow manager

Dimitrios Ntoupas

Communication manager

WE ARE...

ABSTRACT The efficiency of PV panels decrease after they attain a temperature of 35 degrees. The project aims to prevent the effect of heat on the PV panels in the façade of the buildings, using water to design an evaporative passive cooling system. A system of clay mixture and PV cells is proposed with clay playing the role of water absorbent.

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The module proposed is assembled to a system that can work both as a second skin in the façade of a building and as an exterior wall separator. The design enables different aesthetic approaches and may also serve as a cooling system not just for the PV panels but also for the building’s facade. As for the application context we considered warm and dry climates like India.

Project Timeline //

Elevator Pitch 22 09

Concept Development 06 10

29 10

Brainstorm on Adaptive facade

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Christen Jetten

Exploring construction techniques

3d printing

03 11

20 10

13 10

Research

27 11

Research

Concept Adaptation 01 12

17 11

10 11

First Design

Presentation Drawings

Building Weeks II

12 01

15 12

24 12

08 12

05 01

19 01

Moulding Company

Building Weeks I

Final Prototype

Report Writing

Project // Table of Contents

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Elevator Pitch //

Juan Sebastian

Jens Slagter JENS

Dimitrios Ntoupas

SLAGTER

cold PV-p cond Hea anels itions t sta stay ys in clos side ed

war PV-pm cond natu anels itions ral v curl anti open latio n

able to open manually

Imagine a material with moisture- sensitivity ability that could be use in a sustainable climate responsive façade systems. One example of this mechanic is the opening and closing of pine cones . Now, what if we implement this strategy with the use of solar cells in facades of hot weather countries.

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A autonomous façade system that needs no energy and greatly reduce the heating and cooling demand. A smart system that uses bi-metals to passively adapt to different conditions and generates energy through integrated PV-cells.

The final objective of my proposal is to intergrade photovoltaic panels and their maintenance system into one mechanism in order to optimize their performance. Water in combination with the absorptive properties of the sponge is the key element of my vision.

Elevator Pitches //

Stella Pavlidou

Rhea Ishani

3D ROTATED SOLAR SHADERS STELLA PAVLIDOU 5385571

why?? best performance!!

how?? 3d rotation!!

The goal of this proposal is to maximize the performance of the PV panel. That ideally happens when light is direct, meaning that the normal of the solar panel’s surface matches the direction of sunrays. This condition is achieved by a system that allows the 3d rotation of the PV panel.

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To waive the challenge of aesthetics, I present to you the Kinetic façade. It is a combination of 2 modules, a local material (such as terracotta in the given example) and PV to harvest solar energy. The PV panels generate huge amounts of heat which will be dissipated by the terracotta modules.

Preliminary Ideas //

Adaptive Facades

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Clipping & Water system Exploring geometries

01|RESEARCH

how to cool the pv panels?

The idea was to find innovative solutions to cool the PV panels to optimize their efficiency. This phase was a series of asking questions and seeking answers through case studies.

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Brain dump //

1.1 Problem Statement PV panels do not generate their full potential energy if they exceed a specific temperature.

OUR VISION The ultimate goal is to optimize the PV-panel’s efficiency on facades by creating a passive cooling system that uses evaporation-cooling methods and ventilation to tackle overheating. Due to the high absorption rate of the clay, we aim to

OUR APPROACH

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design a modular system that combines PV with ceramic-based materials. The parameterization of the design process allows us to create numerous alternative shapes and forms, according to the context and the climate.

Brain dump //

Design Criteria Modular component

The module should not weigh more than 20 kg. (27 Kg = max allowable weight that an average person can carry)

Sustainable and reusable components

The temperature of the PV panel should not exceed over 35 C, as it reduces its efficiency.

Easily assembled and reassembled system

The module should be designed to capture rainwater for 2 hours and evaporate in 3 days

Passive cooling system

HARD

Customized modules according to climate

CRITERIA

SOFT

CRITERIA

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Cost and production effectiveness Aesthetics

Brain dump //

Mind map

GOALS •To optimise the performance of the PV panel • The possibility of using Terracotta / Ceramics for cooling of PV panels • To design an effecient facade

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Research Questions //

Q1: How to use PV panel on a facade? From solar cell arrayconnetion techiques From solar cell to array 1. Determine sizetoand Solar cell

Module

Panel on the same frame

(Image of lecture P. Manganiello, H. Ziar, 2020) showing difference between solar cell, panel and connections

2. Avoid self shading

Electrically connected panels: STRING

Array 26

3. Eliminate scope for collection of dust

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A PV-panel is made up of smaller modules. These are made up out of many solar cells. When applying on a facade the pannels need to be interconnected. There are different ways of doing this as well as different kind of solar cells (see next page)

(Information of lecture P. Manganiello, H. Ziar, 2020) showing difference between solar cell, panel and connections

The efficiency is unproportionally reduced when the PV is partially shaded. When applied on a facade, shading from other buildings and self shading needs to be avoided.

Small layers of dust can settle on a PV-Panel. This reduces the amount of solar radiantion income and can damage the PV cells. This can be avoided by washing (rain will also suffice) it regularly or applying certain foils.

Research // Categories of PV cells

PV CELLS TYPES

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Research // Circularity // PV Panels

Circularity of PV PANELS Collecting solar energy is an inexpensive and environmentally friendly source when solar panels have not reached the end of their lifetime. Regular solar panels have a lifespan of about 30 years. If we think that photovoltaic panels are a relatively recent discovery, we can conclude that if there is not a circular approach in using them they can potentially create environmental issues as well.

REGULAR SOLAR PANELS HAVE A LIFESPAN OF ABOUT 30 YEARS. If we do not start recycling/downcycling solar panels, they will end up in large landfills and therefore disposing solar panels can result in significant pollution and health issues since they contain heavy metals like cadmium and lead that are toxic. It is quite obvious though, that the most materials that a solar panel is composed of can be recycled on their own. Glass, metal and wiring can all be recycled and reused.

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As far as silicon cells are concerned, even if the silicon wafers are not recyclable, some recycling companies can melt them down and reclaim the silicon and various metals. The process in which materials are separated require advanced machinery, since the difficulty in recycling them is that they need to be separated and thus it is potentially an expensive process with todays’ technologies. Fortunately the first steps have already been done. In July 2018 Veolia and PV CYCLE opened the first recycling factory in Europe for end-of-life solar panels and even in its first year the plant treated 1800 metric tons of materials.

source: www.greenmatch.co.uk

Research Questions // Passive Cooling Techniques

Q2: How to improve the performance of a PV panel? After attaining a temperature of 35 C degrees , the performance of the PV panel decreases. Over time, curing the life cycle, The heat of the sun can melt the solar cells. A large amount of irradiated energy that falls on the PV panel (up to 87%) converts into heat. (Grubišić-

Čabo et al., 2016). Many cooling techniques (passive and active) have been experimented with to achieve a higher electrical output. The challenge was to integrate the cooling system and the PV in one component that can be applied on a facade.

Passive Cooling Techniques

AFTER ATTAINING A TEMPERATURE OF 35 C DEGREES , THE PERFORMANCE OF THE PV PANEL DECREASES.

Passive Cooling addresses all of the existing creative energyless means of keeping buildings cool. Unlike passive heating, which draws on the sun, passive cooling relies on three natural heat sinks - the sky, the atmosphere, and the earth to achieve temperature moderation.The next part discusses the implementation potential of the different techniques. Our perspective is the implementation on facades as well as effectively cooling down the PV panels. 1 — 8

Passive cooling methods //

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Solar and heat protection

The main idea of this technique is to keep the incoming heat away. This can be done using 2 methodes: • Creating a Micro-climate • Solar income control

Having a micro-climate with vegetation and water is not very suitable for facade integration. Although it is a very sustainable solution, it can only be applied on a small scale (water on roof or small buckets, and plants growing on the facade). The potential of cooling down a PVpanel however is usefull. It does not affect the efficiency and does cool it down (you can compare it with the rising temperature in cities in relation to country-side)

Controlling solar income. There are 3 ways of doing this (glazing, aperture and shading). Glazing is very efficient in reducing temperature indoors by blocking certain radiation frequencies. Aperture is limiting the sunlight to enter only through certain parts. Shading is a very effective technique as well, only cannot be used for cooling down PVpanels. They are all very suited in a facade, but solar income, should be as high as possible. Therefore we cannot lower the temperature by using these 3 techniques.

Passive cooling methods //

(Rongen, L. 2012)

Heat modulation

By heat modulation the temperature is reduced by using either heat storage or by adding free cooling. This is for instance cooling at night or using geothermal heat exchange. It is based on the fact of lower external temperatures

Phase changing materials or thermal mass. PCM is a modern technique to incorporate in an envelope to cool a building downs, while thermal mass is a very tradional way.It is both an effective way and many materials can be picked for the PCM according to their prefered properties. The facade integration is therefore ideal for PCM, but it will be very heavy when thermal mass is used. The PV-intergration is already being used (P. Manganiello, H. Ziar, 2020). This is therefore a very suitable technique to be incorporated. This can be located in the pv, the elements, the original facade or anywhere near the PV-panel. This allows a lot of design freedom. (Saffari et. al, 2017)

Free cooling. This method is very old and uses the temperature difference between day and night or even between seasons. Since this is free and no additional action can be taken to increase this, we do not have to take this into account for PV / facade integration (Rongen, L. 2012)

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Passive cooling methods //

Heat

(Santamouris & Kolokotsa, 2013, p. 84)

dissipation

“heat dissipation techniques deal with the potential for disposal of excess heat of the building to an environmental sink of lower temperature, like the ground, water, and ambient air or sky”

Convective cooling. This methode is using the transportation of air to cool elements down. Like blowing over a cup of hot tea. This movement of air can be initiated by pressure differences. A building experiences different kind of these like : buoyancy effect, trombe walls, chimney effect or wind driven ventilation. This technique can go very well with pv cells. An effective way of cooling down without reducing the efficiency or damaging the solar cells. It can also remove dust laying on the surface of the PV-panel. Evaporative cooling. Water functions as a heat exchanger. Moisturizing the air will allow more heat to be stored. Evaporative cooling can go direct or indirect. Direct meaning that water is added to the air, indirect meaning that water creates a wet chanel that cools the air down (not wetting the air). In order to achieve this on a facade, water would need to be supplied to the facade. This water can be rainwater that is caught on the facade, or transported water from a pond. This technique is very suitable for pv. Not only because it does not interfere with the working of a PV panel, but also because it can clean the surface of any dust. (Baca et. al., 2011)

Radiative cooling. Peak temperatures of the PV-cell occur during daytime and daytime radiative cooling has not been achieved so far. Radiative cooling is thus not suitable. (Nilsson et. al., 1995) (Raman et. al., 2014)

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Passive cooling methodes //

Summary of possible cooling methods

Increase convection • Increase the amount / change pressure of air • Increase velocity of air that moves over or under the pv-panel • Redirect air towards panel

Maximize radiation income • Remove self shading • Find perfect inclination • Suitable for various facades and orientations

Increase evaporative cooling | capture water

• Supply water • Water buckets • PCM • Ceramics (hydroscopic character)

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Research // Material Properties

Q3: How can the absorption of Clay be increased? Clay - Natural Mix

Clay - Charcoal

Clay - Sawdust

• Firing temperature: 900 - 1100 °C. • Porosity ratio: 0.067 μm - 0.637 μm • Maximum T - Difference 1.2 °C

• Firing temperature: 900 - 1000 °C. • Porosity ratio: 0.154 μm - 0.166 μm • Maximum T - Difference 3.2 °C.

• Firing temperature: 950 °C. • Porosity ratio: 0.25 μm - 0.26 μm • Maximum T - Difference 2.5 °C.

ADVANTAGES

• Can be used in a passive cooling system

• It has a higher absorption rate. (3x faster)

• Higher insulation capacity • Calorific power combustion • Less embodied energy in the firing process • Lighter components • Higher porosity

(Chemani and Chemani 2013) | (Katsuki et al. 2018)

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Material Porosity

Research // The process

Production Cycle

RAW MATERIAL 40 million tons of raw material produce in excavations.

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MANUFACTURE

FIRING CLAY

COMPONENTS

Increases the porosity properties of clay as building component.

Develop a natural PV-cooling facade component

THE PROCESS

The Initial model making experiments involved using ‘kit Pistool’.

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Research Questions // Circularity of Clay

Q4: Is Clay circular?

IS IT POSSIBLE TO RECYCLE FIRED CLAY- HOW CAN IT BE RE-USED? BASED MATERIALS? An Indian artist, Shashank Nimka, uses a set of procedure to reuse Fired clay is not biodegradable, thus the answer is no. Once you fire a piece of clay, chemical changes happen. Firstly, chemically firing the water cannot be replaced. Secondly, once fired, clay particles are being ‘vitrified’. In other words, particles melt and fuse together. Green ware, which is the clay that has been dried and not fired, can always be turned into clay again.

Downcycling process of fired clay. 1 — 16

fired clay. First, he crushed the broken ceramic pieces in order to create a powder called grog. After that, this is mixed with a small quantity of virgin clay which acts like a binder. This is then blended with water and some minerals that act as deflocculant and the mixture is liquefied. This slip, is then cast in molds and allowed to settle. Once dry, the ceramic products is taken of the molds and thus many objects can be created. The applications range from tableware to lifestyle accessories, from architectural elements to furniture. These new products are easy to maintain and are also weather resistant .

Research Questions // Case Studies

ANT STUDIO, India

The Studio aims to bridge the friendly is a ‘evaporative passive gap between craft and machinery cooling system’ created together thereby, embracing all the spheres with local craftsman. of Art, Architecture technology & materiality fusing with nature. INFERENCE

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The concept was derived from reading on how Egyptians fanned the porous jar of water to get cool air. The ideas from the past were analysed and assimilated to build a ‘hive’ with earthern cones; a sustainable resource to cool the air. In India, heat waves are prevalent during summer months. This eco-

• Passive cooling technique is possible in Terracotta (Ceramics) • Water and Cermaics can be integrated to achieve passive cooling. • The water management system must be designed with care to avoid wastage. Deki Cooling Installation. (n.d.). Retrieved January 29, 2021, from http://ant.studio/beehive/ qy4z4lq8uradkygqlbsj43lhbughe1v

Research Questions // Defining the location

Q5: Which regions in the World have a high PV potential?

Climatic Zone

Hot and Dry

Warm & Humid

Temperate

Cold

Composite

Cities Jaipur Rajasthan Madhya Pradesh Central Maharashtra Ahemdabad Chennai Mumbai Kerala Coastal part of Orissa

Bangalore Goa Deccan Jammu Kashmir Ladakh Sikkim Himachal Pradesh New Delhi Punjab Uttar Pradesh Bihar Jharkhand

Description High Temperature Low Humidity High/intense solar radiation Clear sky Moderate tempertaure Moderate humidity (day) High humidity (night) Diffuse solar radiation/cloud Direct solar radiation\cloudless Moderate tempertaure Moderate humidity (day) Clear sky (throughout the year) Low tempertaure in winter High solar radiation low humidity on cold sunny days High humidity on cold sunny days High Temperature in Summer Low tempertaure at night Low humidity in Summer High humidity in Winter High Solar Radiation

Summer Day Night

Winter Diurnal Variation Humidity Day Night

40-45 20-30 05 25 0-10

15-20

20-40 %

Av. Max.Temp.

32/19

40-60% (day) 30-35 25-30 25-30 20-25

5 8

33/24 75-95% (night)

30-34 17-24 27-33 16-18

8 13

60-85%

29/19

10-50% 17-30

4 21

4 8

3 4

15-25

20 7 68-70%

32-43 27-32 10 25 4 10

40-90%

32/19

CLIMATIC ZONES IN INDIA

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LOCATION

Q5: World map comparison variables Temperature In order to choose a location for our design (according to our problem statement), we required more information than just knowing about the regions of the world that have high PV-potential. Temperature and water are important factors take into consideration. After overlaying all the maps some countries/regions were qualified to suit our analysis for example: - Mexico - Chille - Sout Africa - Saudi Arabia - INDIA - South East Asia

Rainfall

1 (Based upon FAO(2020) statistics data & mapping) — 19

These countries have a high PV-Potential. They experience ‘high’ temperatures and moderate to heavy rainfall. These are not the places with extreme climates. We decided that we need some parameters to work with. Thats why the ‘hottest’ places and the ‘dry’ places are eliminated from the selection.

Research // Defining the Location // Asia

Looking Closer.... We picked South India as a reference location. When we take a closer look at the map of India we marked specific regions to gather data from. The north of India can experience high fluctuations in weather due to windward side of the Himalayan mountain ranges. When we go a little more south we first experience the Deccan Plateau of India. We did not want to pick a spot next to the ocean since the salty wind influences the temperature, wind and humidity of the air. We picked Bengaluru (the green dot at the bottom of the left image). It is a Megacity with Software parks and high Residential towers. EPW and IWEC files are open sources accesible and documentation of the city is up to date and goes far back giving the perfect conditions as a reference location.

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02|RESEARCH BY DESIGN THE FIRST 3D PRINTED MODEL

After all the literature research, we came up with a design that integrated all our concepts. This was our first 3D printed model.

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Water Management Part one is to gather water in order to use evaporative cooling. Water can be obtained by either catching the rainwater, using water from the building or having an external water body. We decided that it would be best capturing the rainwater. This process left us with back the first problemwhich was “How to actually catch rainwater on a facade?” The water is falling down and slashes on the panel. If the panel is to flat, the water will be spashed in all dicrections (see image on left top. If the corners are not to angled and the surface is sort of steep the water will not splash, but rest on the panel before moving down. After the water moves down we want to make sure it does not only end up at the bottom and flow. We solved this by pumping it all the way back up again. While this Cycle continues all elements will be fully saturated (see image on left bottom).

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draining it just beneath the solar panel. Then there is one stream guiding to one outlet at the bottom

1.1

Now we decided how to capture the rainwater and how to distribute it. The next (and final) step is to find a way to saturate the panel. There are 2 things that need to be designed and there are several ways to design them. 1) Local rainwater inlet or external transportation (outlet) 2) Internal rainwater transportation and absorbtion

Letting the rain fall over the whole panel and collect it at the very bottom. There it is collected into one outlet

2.1

2.2

2.3

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1.2

In our final design we decided that a combination of 1.2 and 2.3 would give us the best saturation and makes the molding proces a lot easier.

The water is dropped down at one point. From there it travels through cavities or channels in the middle of the element to one outlet

The water is inserted at 2 points. From there it dripples through the side of the element to two outlets at the bottom

The water enters from one inlet and gets distributed along the panel. It then dripples everywhere from top to bottom. Once at the bottom, some kind of fossit is needed to gather the water again. Front view

Side view

Research by Design // Concepts

Computational Analysis

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The initial concept of this design is to create an aesthetic pleasing ceramic component by lofting and rotating two rectangular surfaces. The smallest one is proposed to be the pv panel. Even though the aesthetic result was pleasing Air flow and water mechanisms were difficult to be integrated in the design successfully and therefore it was left behind.

Research by Design // Concepts

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Research by Design // Concepts

The design is based upon the joining of two elements. By placing them next to eachother a channel is constructed that pushes the outside wind into the cavity giving it an upward boost. The pv-panel is inclinde giving it the perfect angle in relation to the sun’s average position. On the bottom of the pv-panel there is a drainage system that captures the rainfall and transports it through a cavity in the element to the back (long absorbtion path). This same cavity is used to guite the wind of the chimney effect over the panel. When this is completed it is joined with the outside wind and is directed back into the ‘chimney’. This way the air over the panel gets cooled by indirect cooling of the ceramics and part of it uses direct evaporation of the water still in the cavity. Water gets transferred down into the element below while wind travels up to the element above.

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Research by Design // Concepts

This concept takes into account the water circulation. Water enters in the front of the brick, through a slop and then it drops to next brick bellow. There, it is slowly being absorbed. The shape of the module also allows an inclination to the pv panel for better efficiency in south facade. 1 — 7

Research by Design // Concepts

The design is based upon creating a more freeform geometry. By having oval shape designs the aim was to guide the outside air towards the cavity. Water can be transported downwards in a fluent trajectory falling from one object to another. Thin-film PV is used to create the free-form structures.

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How?

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pv area

water

wind

weight

aesthetic

molding

Research by Design // Concepts

First prototype

Limitations Clipping system will not support the piece.

Diagonals directions casting.

in lock

two the

Narrow corners are too brittle

Design not suitable for industrialisation. 1 — 10

03|STUDIO CHRISTINE JETTEN THE CERAMIC ARTIST

02 | CHRISTEN JETTEN STUDIO

In collaboration with Ceramic Artist, Christen Jetten we were able to understand the ceramic and the moulding industry,. Thanks to her, we could successfully produce our fully functional working prototype !!!!!

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Christen Jetten // Understanding the material

Christen Jetten, Artist Christine Jetten is an artist who has ingrained art, education, and culture philosophy through her experiments with ceramics. As a sculpture artist, she was always interested in Architecture and keen on learning the influence of a space on the senses of a human being. She started her career as a professor of Art History. Through the years of her professional career, she deeply felt the need to further develop her own philosophy, and delve in material research.

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“She began her research on weather resistant materials in clay and glazes to make positive interventions in the production process.With a fascinating experience in the façade industry, the artist has been a source of immense inspiration for us to explore the sensibility of the materiality, and to contemplate the impact of the texture and simplicity of ceramics on the human. Having the pleasure to learn from her was a gratifying experience both as a student and professional. The World of Ceramics that Christine presented to us surpassed our expectations of the scope of the material. She has opened her studio to help the team to explore the potential of clay in the building industry. We take with us, a small ounce of her passion, dedication and unceasing determination to always teach & learn. With this we want to dedicate everything that we learnt about ceramics through this project to her.”

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Research // The Industry of Ceramics // The Specialist

Material Understanding

SHRINKING As a natural effect, clay reduces its shape once the drying process starts, eliminating the mixture’s moistures by evaporation. On a molecular scale, the clay particles drawn closer together, resulting in a shrinking effect of the total volume.

INCREASING POROSITY DRYING

KILN

STEP 1 THE SHRINKING EFFECT

The shrinking effect is used in the research to maximize the porosity ratio in the experimental mixtures. By adding several binders, we aimed to find elements that do not react in the shrinking effect. Consequently, producing the particles of clay to move around the components to created gaps.

INCREASING POROSITY STEP 2 KILN PROCESS

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The research aims to validate the effect of wood as a principal catalytic binder for porosity. This material would reach the kiln process, creating a combustion effect that burns and leaves gaps in the ceramic.

Research // The Industry of Ceramics // The Specialist

The first approach to Clay

HAND MOLDING

Working with the hands to understand the traditional clay moulding process

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Using a plaster mould from Christine Jetten Studio, we create our first ceramic tile. The purpose of these exercises is to identify clay’s material physical characteristics and understand the traditional method of handcrafting. After 25 minutes of work, we finally complete the material dispersion of one tile. The process required the constant addition of a small amount of clay, followed by applying finger pressure on top of the mixture to guarantee a homogeneous spreading of the material inside the mould.

Research // The Industry of Ceramics // The Specialist

SELECTION OF CLAY BINDERS FOR POROSITY STIMULATION WHITE CLAY - POWDER

MIXING STAGE 1

White Clay 01795 - SIBELCO We have selected white clay code 01795 from SIBELCO company. This product shows to be the best option in the experimentation due to the recommendable fire kiln temperature, (1000 - 1300 degrees celsius). The original composition of the product with 40 % chamotte in small particles ( 0 - 2,0 mm ) stimulates a small percentage of porosity.

CHAMOTTE - LARGE PARTICLES Reusable crush ceramic

DRYING STAGE 2

Chamotte is recycling fire ceramic; this process grinds and screens the material to specific size particles. This component commonly used for pottery or sculpture is selected to research binders’ effects in the clay drying process. Thus, using large particles, the goal is to allow the clay to shrink in the drying process around the grains, due to the absence of moisture in the chamotte, the clay will contract the particles leaving some gaps around it.

SAWDUST - LARGE PARTICLES Material waste from wood work Wood particles aim to create gaps in the ceramic kiln process. The large particles of wood will burn in the first stages of the kiln. As a result of the material’s ignition ( between 0 - 150 degrees), the mixture will create gaps in the solidification process.

(Chemani and Chemani 2013) | (Katsuki et al. 2018)

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KILN STAGE 3

Research // The Industry of Ceramics // The Specialist

CIRCULARITY IN DESIGN

CHAMOTTE - LARGE PARTICLES

Reusable crush ceramic

WHITE CLAY - POWDER

White Clay 01795 - SIBELCO

SAWDUST - LARGE PARTICLES

Material waste wood work

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Research // The Industry of Ceramics // The Specialist

Analisys of clay bodies vs moulding process LIQUID CLAY

SOLID CLAY

HOMOGENOUS BINDER MIX

95 %

70 %

MOULDING TIME FRAME

30 %

100 %

SHAPE COMPLEXITY

10 %

35 %

MOULD SIMPLICITY

80 %

10 %

Hand process

Handcrafting

Geometry factor

INDUSTRIALIZATION

90 %

METHOD SELECTED !!! 1 — 8

MOLDING LIQUID CLAY DESCRIPTION OF THE PROCESS The texture of the liquid clay is similar to milk or yoghurt. With this clay body, in the moulding process is necessary to fill the mould to the top. Over time, the plaster which is a material characteristic of the mould. Will absorb the water that contains the clay, and progressively creates a hard layer around the mould.

The ceramic thickness is determined by the amount of time the clay is in contact with the plaster. Therefore, a longer time in contact with the plaster, thicker ceramic piece. Once the ceramic reaches the desired thickness, the withdrawn take place to eliminate the remaining material.

Casting of complex geometries LIQUID CLAY

CONCLUSION Due to the liquid having a lower density than other binders like wood or chamotte, the heavier elements sink at the bottom of the mould. Therefore, this process is not suitable to create a homogenous mixture. 1 — 9

MOLDING SOLID CLAY

SOLID CLAY

CONCLUSION This method proved to be the best option for the material mix. Thus, allowing an even mixture of binders along the volume, the research uses the same process to create simple ceramic shapes for experimentation.

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DESCRIPTION OF THE PROCESS Solid clay is considerably denser compare to liquid bodies. This material can present the same characteristics as playdoh, where hand moulding takes place to shape simple geometries. Due to the hardness of the product, the shaping process uses simple moulds. Consequently, this system produces simple shapes. One advantage of this process is the homogenous mix of materials with a high density such as rocks, or sawdust. The hand process of clay addition requites a subsequence deposition of the material in small amounts. The continuous pressure application guarantees an equal dispersion and saturation of the mould shapes.

PREPARATION OF THE MATERIAL PHASE 1

PHASE 2

PHASE 3

PHASE 4

PREPARING BINDERS

MEASURING PROPORTIONS

MIXING

MOISTURE ELIMINATION HAND MOULDING

RECOMMENDATIONS

Guarantee a homogeneous mixture is required to give to the composition an even drying phase.

For the binders’ measurement, we have used a lab cup of 600 ml to find the percentage of the mixture in a volume proportion. Thus, using as guide 300 ml for each sample, the process creates baches of several variations to determine the best combination.

To create a clay paste is necessary to add water to the previously measured samples. The progressive addition of water makes a liquid paste similar to icecream or concrete. Is essential to create a mixture not to wed or to dry.

The clay paste needs to dry in a plaster plate for 20 minutes. To apply the material into the plate, just spread the liquid on top of the surface. Try to shape a 5 mm thickness circle. This step will guarantee the material to partially dry, allowing the mix to be mouldable. Finally, the result looks and feel like doo. Is recommendable to hand mould the past for a couple of minutes of guarantee consistency.

The hand process of clay addition requites a subsequence deposition of the material in small amounts. The continuous pressure application guarantees an equal dispersion and saturation of the mould shapes. Special attention to the corners of the shape is necessary to fill the mould.

It is Cut and put and

necessary to crush the clay. the solid clay in sections let it dry overnight. Then, the pieces in a plastic bag grind up with a hummer.

RISK Not following this step leads to create cracks in the Kiln process

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RISK The test neglected the weight of the binders to create a more even mixture.

Unfortunately, the water amount does not follow any standard. This process requited observation criteria to determine the best result of the mix. Advice, try and error, go slow in this step. Adding an excessive amount of water can create a liquid mixture. ever, this mistake can be solved, letting the mixture dry for an hour.

PHASE 5

Use the fingers to apply pressure on the clay. Adding pieces in other sections of the mould will create cracks. Always add more clay on top.

Research // The Industry of Ceramics // Learning Process

Ceramic molds are generally made out of plaster, this is an optimus material to absorb moisture and water out of the clay mixture. Helping to speed up the drying process that can take weeks depending on the dimension and thickness of the piece.

FLORIS HOVERS

APPLICATION This piece design by Floris Hovers shows the typical imagery of cast engine blocks, as an inspiration to create ceramic pieces where engine blocks and housings are predominantly cast in aluminium or steel. In this case, the artist explores the possibilities of ceramic materials. The two parts are connected, employing a gasket and various screwing moments. Inspired by these pieces, the photoceramic project aims to create a dry join system that allows the module to increase or decrease.

1 — 12

Research // The Industry of Ceramics // Learning process

ASSESMENT OF GEOMETRY

Clipping system will not support the piece.

Diagonals directions casting.

in lock

two the

Narrow corners are too brittle

Design not suitable for industrialisation.

1 — 13

04|EXPERIMENTATION PHASE wind | radiation |water through the material

Through research, we found three parameters; wind, radiation & water, that could be incorporated as concepts to increase the efficiency of PV panels. To acheive this, we performed a series of experiments.

1 — 1

Research // The Industry of Ceramics // Learning process

MIXING type 1 item chamotte white clay 01795 water saw dust chamotte white clay 01795 water saw dust chamotte white clay 01795 water saw dust

1 — 2

characteristic % bake clay crush and reuse into the mix from the factory, binder with clay and chamote , especific mix hot Big particles type 2 bake clay crush and reuse into the mix from the factory, binder with clay and chamote , especific mix hot Big particles type 3 bake clay crush and reuse into the mix from the factory, binder with clay and chamote , especific mix hot Big particles

10%

RECOMMENDATIONS

ml. volume Kiln 39.5 30

65%

250

195

1080

25%

4.06

900

15%

60%

180

1080

25%

900

15% 35% 50%

136.13 -

45 105

1080

150

900

The following table shows the binder proportions in regards to material ratios. For the experimentation, three selections of components aim to identify optimum combination for porosity and cohesion. Thus, Using large chamotte particles from 10% to 15 %, sawdust in large particles 25 % to 50%, and solid clay, we created six samples. Half group (type 1, 2, 3 ) were kiln at 900 degrees celsius, and the remain pieces at 1060. This experimentation aims to prove the influence of wood particle in the stimulation of porosity and temperature in porous dimension.

Research // The Industry of Ceramics // Learning process

Assessing the geometry

A line is marked and measure in the fresh clay piece. Once the specimen is dry, the line is measure again to compare shrinkage capacity of the mix. For the experimental case, the effect of contractions is not superior to 3%, and therefore this consideration is neglected in the experiment process.

MEASURING SHRINKAGE

STEP 1 - CHECK DRYING STAGE

STEP 2 - DE-CAST THE CERAMIC

STEP 3 - MEASURE ORIGINAL PIECE

STEP 4 - SPLIT SAMPLE FOR KILN VARIATIONS

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Research // The Industry of Ceramics // Learning process

Assessing the geometry

STEP 1 TYPE 1

TYPE 2

TYPE 3

Measure weight pieces dry.

ceramic

PROCESS AND CONCLUSION The purpose of this experiment aims to evaluate the abortion ratio of the different ceramic types

900 C STEP 2

Overnight soak the ceramic piece (12 hours)

STEP 3

Measure weight ceramic soak piece

TYPE 1

TYPE 2

This experiment shows that specimens with higher wood quantity were not superior compared to other samples. On the contrary, the pieces with higher wood content were likely to have less mixture cohesion. Conversely, specimens with higher chamotte content presented increment of absorption capacities, in comparison with sawdust. As seen in type 2 and type3, were the wood content is considerably higher. Nevertheless, the difference in abortion capacity is just 1%.

TYPE 3

1060 C type

type

1 — 4

1 2 3

kiln T

ceramic absorption test type A 1100 initial weight 2nd weight (34 h ) water absorbed % water test vol. 900 107 124 17 16 500 ml 900 95 117 22 23 500 ml 900 140 174 34 24 500 ml

ceramic absorption test type A 1100 initial weight 2nd weight (34 h ) water absorbed % water test vol. 1060 102 117 15 15 500 ml 1060 90 105 15 17 500 ml 1060 135 155 20 15 500 ml

KILN PROCESS LEARNING PROCESS

SAWDUST BURN ANALISYS The specimen contains 50 % of sawdust, 35 % solid clay, and 15 % chamotte. Material cohesion in the mix is insufficient when saturation the ceramic with water the piece partially collapse. Is evident that the ceramic lack of mechanical properties. abortion ratio (24%)

TYPE 3

SAWDUST BURN ANALISYS The specimen contains 25 % of sawdust, 60 % solid clay, and 15 % chamotte. Material cohesion in the mix is superior compare to the previous sample. The absorption experiment results show an improvement in porosity ratio. Despite the decrement of wood particles, chamotte proof to be an efficient component to stimulate porosity ratio. abortion ratio (23%)

PARTICLES SIZE 1.6 MM SAWDUST T 950 C Drying Shrinkage Moisture of paste (%)

Firing shrinkage (%) x10

Absortion (%) x 10

Bulk density (g/cm)

Bending Strenght (Kgf/cm2) x 100

PHYSICAL AND MECHANICAL PROPERTIES

1.8

TYPE 2

1.6

1.4

1.2

0.8

0.6

MOISTURE OF PASTE (%)

1 — 5

SAWDUST BURN ANALISYS

TYPE 1

The specimen contains 25 % of sawdust, 65 % solid clay, and 10 % chamotte. Material cohesion in the mix is considerably compact in comparison with type 2 and type 3. The absorption experiment shows the lowes absorption results despite reducing the chamotte amount by just 5 %. This sample reinforces the idea of chamotte as a principal binder for porosity stimulation. abortion ratio (16%)

04|EXPERIMENTATION PHASE COMPUTATIONAL DESIGN ANALYSIS

Integration of Computation Design to optimise our design and make it suitable for the climate of South India.

1 — 6

Research // Computational Analysis

Computational Analysis: Investigating WHAT & WHY??

EPW or IWEC2 to simulate weather conditions

Radiation Amount of evaporation Average temperature Specific air density Max temperatrure

INPUT DATA

IDENTIFING UNCONTROLABLE FACTORS

Thanks to available open sources. We could gather representative data for South India through EPW and IWEC2 files. (EnergyPlus, 2014)

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The output of the data allowed us to quantify the weather parameters. The parameters were then used for heat convection calculations or as input for a script.

Material Geometry

Cooling demand to keep the temparature of panel below 35Celcius

Velocity of air Amount of air PV-angle

DESIRED OUTPUT

PARAMETERIZE CONTROLLABLE FACOTRS

FINAL RESULT

These are the other variables that influence the amount of heat that is being transferred. The script needs to evaluate these aspects and we optimize this using Galapagos to obtain the best result.

When the script is based upon parametric values and they create the geometry together. As a result we can obtain the ideal geometry.

This originated from the problem statement.

The Process

Research // Computational Analysis

Software Research

3D modelling software

Rhinoceros 6.0 (2010): This was used as main design software. This allowed us to use Grasshopper to parameterize the designs. Giving certain parameter and dimensions like angle, width, height and curvature. We had the freedom to change them according to our liking and their effectiveness.

Computational Fluid Dynamics (CFD) SOFTWARE: Butterfly (0.0.05), 2019: This grasshopper plug-in from ladybug allows wind tunnel generation and therefore CFD simulations. However it requires OPENFOAM software (ESI-OpenCFD, 2020). This software only runs on Linux or IOS. Therefore requiring an additional computter with Linux installed borrowd from roommates (see image on the right). OpenFOAM (ESI-OpenCFD et al., 2020) would now run and simulations can be made in there, however Rhino is not functioning very well on Linux. Not allowing us to design easy and thus not a good option. Eddy (0.0.1) (Kastner et al., 2020): A grasshopper and rhino plug-in that simulates ventilation. Usefull for basic architectural aplications, but limited wind simulation options. Therefore not suited for our project.

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Own image: Computer used to run OpenFOAM

Research // Computational Analysis

ArchiDynamics (Karadag, I., & Serteser, N. (2019)): A Rhinoceros 6.0 and grasshopper plug-in that is easy to comprehend and can simulate extensive situations. However this software can be installed, but is not allowed to run without a valid license (see image on right). It is also better suited on a urban scale. SWIFT (v0.1.3), 2017: A grasshopper plug-in that can create a virtual wind tunnle. The calculations are fast and the simulation options diverse. However it runs on OpenFOAM (ESI-OpenCFD et al., 2020), wich poses a problem simular to using the Butterfly component. The external computer could not run Rhino and the ‘normal’ Windows computer could not run OpenFOAM (2020). SWIFT is therefore not suitable either.

Own image: Grasshopper script of ArchiDynamics. Not able to run due to outsources calculation license

Phoenics (1.6), 2020: A stand alone complete airflow analysis software with buildt in 3d modelling. This software is used in other courses during BuckyLab engineering and is therefor familiar and a licence is provided. The amount of geometry design freedom is limited. It is suited for simulations.

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Rhino CFD, (Phoenics (1.6), 2020): A buildt in component in Rhinoceros allowing various phoenics simulations to be run inside rhino. This allowed us to combine the input knowledge gained in other courses and our design expertise in Rhino. Once this program was found, a license to install it on Rhinoceros 6.0 was immediately requested and provided.

Phoenics simulation software (retrieved from Cham.co on 24-01-2021)

Research // Computational Analysis

Weather simulation software

Ladybug (Sadeghipour Roudsari, Mostapha; Pak, Michelle, 2013): This plug-in in grasshopper is used in order to simulate weather data (EPW or IWEC) extracted from EnergyPlus (1996). This can be used to gain insight into temperatures, humidity, radiation, rainfall, sunlight and so on.

1. Getting started: tackling points We started off with defining the dimensions of the ceramic and the solar panel. This included the parts that needed to be parametric. Later on in the proces some of these variables. Since the geometry was not defined yet and we want the most energy output as possible we decided only a few constrais. After this galapagos was used for optimization. 1. We decided that it should be easily remade for a different place in the World. We wanted it to be able to insert a point in the world and that the data from that location will be used

Location specific data

2. The horizontal angle of the solar panel should be parametric 3. The vertical angle as well. This allowed a 3-dimensional optimum.

EPW or IWEC file

4. The maximum weight of a (dry) panel should not exceed 20 kg (volume x density). Since this is the highest weight a construction worker is allowed to carry without any additional support. 5. The placements of the panel need to be adaptable. Sometimes more spacing is desired in order to create a view to the outside. A special grid designer is used here 6. The size of the solar panel should be able to vary. This so not a whole facade will be covered but to make sure there is room for the ventilation- and waterstreams.

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7. The ventilation is a very important factor to cool something down. This needs to be parametric and is done by controlling the sizes of the cavities and holes inside the panel. This way the amount of ventilation can be controlled.

Radiation calculation

Research // Computational Analysis

2. Horizontal rotation

Own image of first horizontal rotation script. Own image of final horizontal oriantation script.

The rotation component itself started off as a mess (see image left). Many components where inserted to get the desired controlable output. The script slowly evolved, meaning we needed lesser components to do the same (see final result on far left). In the end we definded the midpoints of the two horizontal cuves that make up the rectangle. By taking the midpoints and connectint them we create a rotational axis. There are otherways of doing it. The important part is to limit the rotation component so it is always facing in the right way (meaning not to the building).

3. Vertical rotation After the horizontal rotation we needed a vertical one as well (see image on the left). This allowed us a free and smooth 3dimensional rotation. The free rotation poses a problem as well (see image on left). The rectangles intersect with the building. If this is then simulated, the results will not be representative.

Therefore this needed correcting. There was a lot of trail and error in order to get this. The problem lied in the fact that it was unknown how far the panels had to be moved, in what direction and how many points are inside the buidling

The script below left shows how the problem was first tackled (Identifing the points that are in the building and dispatch them. Then measuring the distance of a corner and its original position. This data is gathered and the highest number is taken from the list. All the corner distances are checked to see, if they match with the farthest distand, if this is the case than only that vector is created).

However this method was very unpractical and hard to follow. An easier method was found later. Using the same dispach, but projecting the corner points back to the brep. This movement is stored in a vector and by creating a maximum domain we can only take the biggest vectors. Allowing all rectangles of various sizes to be placed perfectly on the facade.

Own image of vertical rotation and problem explanation

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4. Weight of the panel When considering the weight of the panel we first wanted to generate the design in grasshopper as wel. Giving a constrant to the maximum value. However our design evolved. From one “big” element to smaller sections that can be assembled as one big one. These sections themselves would not exceed the 20 kg maximum. Therefore we do not need to incorporate this in the script.

Massa max = 20

Massa max = 20 * 4

5. Subdividing the facade

Own image: creating gridmapper pattern

Own image: solving orientation and dimension problems

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We wanted to be able to create more spacing between elements at certain places. This because there can be an inner courtyard or a desired view to the outside (see bottom diagram). We wanted to create this with attractors to create a gradient. By using a graphmapper the subdivision is created (see image on the left). This can work in horizontal or vertical directions. By combining them and let them intersect with the facade we

create the small surface division in the facade that is needed to create the pv rectangles. However when splitting the surface with the curves the orientation of all the rectangles are reprogrammed in a random order, not allowing a unified transformation. To reset this orientation we had to reorientate all the plane directions and set the rectangle dimensions back (no negative values or flipped curves)(see image bottom left).

6. Size of the panels Now that we have subdivided the facade into rectangles with similar orientations we can simply rescale them with a factor smaller than one. This is also a variable that should be controlled manually and not by galapagos.

Galapagos will set the panel size to the maximum dimensions since that generates the most output. By grafting the rectangles we can rescale them by selecting the axis that we want them to follow.

7. Ventilation We wanted to control the ventilation amount, velocity and direction. This will have a direct relation to the convection rate and therefor the temperature. However research about optimalisation plug-ins and experience from our

tutors showed us that an optimalisation script in combination with CFD software is not achievable within the scope of this project. Therefor the CFD simulation will have to be done seperately. There will be a further description of this later on.

Running the full script. A single static analysis in ladybug already takes a lot of time to compute. Galapagos doe this computation a lot of times and therefore taking the analysis of the whole facade would be very accurate, but takes also a lot of time. A faster and better option will be to take one represantative surface and insert that one for the ladybug analysis. 1 — 13

Put the rest of the pv panels and building components in there as context. This will increase computation time. However it still can take hours before a valid result is acquired. We computed it in November to gain the pv-angles so we could start designing.

It took 5 small tries to limit all the variables to the correct amount. Then it took 7 hours and 35 minutes to complete. It took 95 evolutions to finally converge into a trustworthy spectrum.The angles that came out were 42 degrees vertical tilt and no horizontal tilt (the facade that we analysed was oriented to the south and located almost at the equator). These values where used to design the element.

The full computation is being run since the 27th of january on a seperate computter. Estimated time of completion is 3 days (special thanks to Meaux 2020)

Research // Computational Analysis

Ventilation

It is hard to grasp the working and the flow of air when we never studied it this closely. We first needed to investigate what airflow are already there. Since we are going to make a second skin facade there are

2 airflow. One is the outside wind, and the other one is the wind between the first and second facade (known as chimney effect).Then comes the aspect of humidifying the air (to increase heat capacity) so it cools down. Own image: Sketch nr. 1

1 — 14

Our ceramic element is design to capture the water and slowly give this back to its surrounding. The air needs to be redirected over, through or past the ceramic element before we want it to flow over the PV-panel. So the next step is taking the existing airflows and redirect them through the element. Until now we identified the present airflows and decided to redirect them through the ceramics. Now the air is humidified, but the speed can be increased. This will also influence the amount of heat exchange. It is like blowing over a hot cup of tea. By pressing the outside wind through a small hole facing ‘angled’ into the cavity we join the two windstreams and give them a boost while joining. This gives us one stream of fast moving humid air. This is the air that the PV-panel surface needs to interact with. The cells that decrease efficiency when temperatures rise are located in the front of the pv-panel. The heat-exchange will be more effective when the air is transported over the top of the pv-panel rather than the bottom. (Chander, S., Purohit, A., Sharma, A., Nehra, S. P., & Dhaka, M. S.,2015).

Own image: Sketch nr. 2

Own image: Sketch nr. 3

Now we hae an understanding of what the air to do, but the issue of how to design this still stands. The sketches are describing the possible airmovement, but some aspects could not be solved just yet and need further research. When the cold and fast moving air passes over the top of the panel it will interact with the outside wind pressure. Giving turbulent air instead of vast moving steady air. This can influence the calculations a lot. At this point it was hard to test the designs, since CFD software license was still being processed and the other free CFD softwares where not easy to understand. We decided that in order to test the airflow we would do smoke machine tests. By applying a smoke machine a visual airstream is created. This allowed us to evalueate the design based upon speed of

SMOKE MACHINE TESTS TESTS DIFFERENT CONCEPTS: • https://youtu.be/K4oPUdw9TK4 • https://youtu.be/MUyTYmufJ_M • https://youtu.be/4ZwOP33Idy4 • https://youtu.be/cHM9B3IwyN0 • https://youtu.be/YkVAmybLs08 • https://youtu.be/jW0K6SWSN-s (back view) • https://youtu.be/nZFLqNq8FsU (back view) • https://youtu.be/raWFTdGraO8 (animation) • https://youtu.be/Gyocm-S07T0 (animation ) • https://youtu.be/CQr8xddfdkk (first test) FINAL DESIGN VIDEOS: • https://youtu.be/7YRGhqhzK9Q (outside wind) • https://youtu.be/AR5UOhQ_N2A (chimney effect) • https://youtu.be/gZWLKxfJlDQ (slow-motion video)

1 — 15

These test where used to evaluate the many designs that we have made. We then rank them and discusses how it can be improved (see ranking of designs image). We used this as basis for our design. Since the CFD software was taking some time, we decided that we would base the design upon visual experimentation with a smoke machine. We use the CFD to simulate a real size situation on a facade.Once we had a final prototype we did smoke test experiments to validate our design in a more practical way. (They are recorded from various angles)

Own image: smoke machine test

Building Weeks // CFD

CFD software | RhinoCFD, CHAM CFD programs are very complex programs to run and to simulate. By using a Rhinoceros 6.0 plug-in we do not need to worry about new ways to construct geometry. However some parameters need to be set within the RhinoCFD and thus far we had just a little knowledge of this. Jean-Luc Overkamp

(a Msc aerospace engineering student graduating in 2 months and also a roommate of Jens) already took 3 courses on how te use this kind of software. With a introduction we were now able to set some general parameters and values. So here follow a short introduction into the software, its options and its results.

(*right click*) about software (*left click*) update license (*right click*)save results (*left click*) load results (*right click*)examine input - gives you a list of data that is being used as input (*left click*) load results - gives you a list of data that summerises the result (*click*)allowes you to add probes. Probes are used as calculation converging verifying points. (*click*)allowes you to change color scale. (*right click*)start/stop recording video (*left click*) result display parameters. Allows you to visualize different results like pressure, velocity (x, y, z) (*right click*) remove visualizations (*left click*) Load result after calculated (*right click*) Run solver, only press if all input is set (*left click*) show convergence plot, when the input is constant you should get the same data for every point in the model. These points are called probes. If the data is getting similar it ‘coverges’ meaning the calculation can be considered complete and valid. (*click*) show or hide probe. (*click*) show or hide grid (*click*) show grid dialog. The grid is the size of the finite element methode that is being used to simulate the dynamics. The samller the gridsize the longer the calculation. The grid width between elements must be of no greater distance than 0,5 * own length. (*right click*) Show table of objects, what properties are assigned to all the objects in the rhino file (*left click*) edit the properties of a single rhino object. (*right click*) edit solution parameter - this component lets you change many values. The image on the right is the tab showing you the type of parameters that you can edit. Geometry --> coordinate systems sources --> gravity or not models--> preset readiation, energy and turbulence descriptions numeric --> amount of iterations and the convergence settings properties --> weather variables initialisation --> restart/start options output --> what variables (i.e. heat transfer coef.) and what format (*left click*) edit domain edge condition - here you can quantify and state how the outer faces of the domain will behave (inlet, outlet, plate ect.)

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(*right click*) create working directory (*left click*) clear all results

own image of solution parameter in RhinoCFD

Detailed parameter description On the image on the right you can see the final setup. The air is set to normal air of 40 degrees celcius (edit dummy fluid with values from ladybug). Barometric pressure is kept at 1 atm. Density air is set to 1.189 kg/m^3. Simulation is set to ONE_PHASE with the free surface, radiation and energy models off (this doesn’t mean it is not seen in the simulation, it means that no specific model is selected so it doesnt affect the simulation).The turbulence model is set to Chen-Kim KE.

This is necessary in order to recieve output values. Here basic constants are defined (Von Karmans, roughness, linarisation, CMU ,C1E ,CD ,C2E ). The output parameters are set to Pressure, Velocity (x, y, z), Turbulent Kinetic Energy and the Dissipation rate of turbulent energy. The location of the probe is of importance. If located in a ‘uninteresting’ region, it can converge to soon, completing the simulation to soon. Therefore putting it in a turbulent area gives better results.

Inlet, Vx = -5 m/s 5% turb int. fluid = air at 40 C

Probe location Blockage (x,y,z) 199 solid allowing fluid -slip at walls

plate domain roughness = 5E-4 m slide velocity (x,y = 0)

Inlet, Vy = 7 m/s 5% turb int. fluid = air at 40 C

Screenshot of rhino moments before simulation

domain within grid location and analysis

(Own images)A vector display showing (Own images)A completely filled field, (Own images)A tube display showing the mixing length scale variable showing the local air velocity the turbulent kinetic energy 1 — 17

Final results The 2 windflow are correctly represented. The chimney effect creates a stronger airflow than the outside wind. You can also see that regarldess of the inlets the outside wind keeps the speed inside the cavity higher. You can also see that the speed is higher when it is closer to the element. Also the wind from the outside hits the front of the panels and gets nicely split in two, traveling to the cavity by passing past the ceramics. This is all sort of according to our expectations. However there are some parts of the simulation that we did not expected

Reflection to see. For instance the decrease in velocity in the cavity. It is not clear if this is because of the programm (no oulet force) or because the outside windflow really decreases the airspeed. If you look closely at the results at the panel level, you can see that there is way more turbulent air than expected. The air from the cavity gets redirected and maintains it speed all the way to the solar panel. However when it needs to pass over the panel, the outside wind interferes. This creates the circular turbulent airstream that you can see at the bottom right panel

The programm was not flawless. It has just been released for Rhino and there haven’t been a lot of new versions. This transfers back to the interaction between Rhino geometry and the calculations of CFD. For instance the inlets can be set from the boundry, but in that case you can only have 1 inlet in total. When having objects working as in/outlets you need to create two closed polysurfaces and place them inside oneanother. Only then can you create a input our oulet. This made the programm very hard to work with. However after 11 full simulations, there is finally a right result with trustworthy convergence plots (see next page). The visualizations are very easy to read (see next page and images below)

Close up view of final result

1 — 18

Overview image of final result

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Validation of results

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You have to check the results and the progress to know if the final values can be trusted. There are 2 ways of doing this. You can check if the residual error [%] in the convergence information summary report is within limits (0-5%). Or you can check the progress report when the simulation is running (the images below). If the converge

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the simulation will have a correct result. In the diagram on the bottom right you can see 2 lines that do not converge. This is the case because the pressure does not change in the simulatin and becasue there is limitted to no horizontal velocity of air. The program can then not improve the result and you will see that in the plot.

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Convergence report of the simulation. A residual error between 0 and 5% is trustwurthy. The fact that the P1 gives a residual error much higher is because the atmospheric pressure does not change that much (since this model has been 1 — turned off) 19

Correctional plot during simulation. You If they do you should get a convergence have to check the representative values plot (on the right). If they do not (middle (P!, U1, W1 ect.) and see if the corrections image), then your results will be incorrect solve themselves.

Research // Computational Analysis

EPW or IWEC2 to simulate weather conditions

Radiation Amount of evaporation Average temperature Specific air density Max temperatrure

INPUT DATA

IDENTIFING UNCONTROLABLE FACTORS

Cooling demand to keep the temparature of panel below 35Celcius

Velocity of air Amount of air PV-angle

DESIRED OUTPUT

PARAMETERIZE CONTROLLABLE FACOTRS

Reflection The original approach to cover the computational part turned out to be very helpfull. However, its function was more of a strategy than a plan. It showed us what we needed to identify or design. We could not turn everything into one script. The current script and 3dm file is already quite big and the optimalisation tool is already taking up ‘days’ to get a good calculation. If everything needs to be incorporated then more steps would be needed to fill the gap between programms, software and data. This takes up a lot of time and energy. It is very nice that we where able to do this for the Ladybug - Galapagos optimalization. To also prepare the grasshopper script to give an output suited for the CFD siumulation would require a lot more time. For now we believe that this is the biggest computational setup possible within the scope of the buckylab. 1 — 20

Material Geometry

FINAL RESULT

05|THE FINAL PROTOTYPE ARRIVING AT A FINAL DESIGN

Through Research and Experimentation, we finally arrived at the design of our Final Prototype.

1 — 1

Research by Design // Comments from Christen

Crit on the two final concepts OPTION 1

OPTION 2 • In the case of Industrialisation of the product, the process of Extrusion is efficient and affordable than others such as Hydraulic moulds. • The clay sections cannot be thinner than 12mm. For thickness around 12mm the physical properties such as mechanical strength, durability cannot be determined. • In case of option 1, the core of the product would take much longer to dry. This could not be executed over a period of 2 building weeks. • Taking into consideration the drying process, it takes a shorter time to dry if the back face was open. In that case, the important quality of absorption would be compromised. • In case of option 2, the thinner sections would dry faster and it would be easy to handle the product in smaller sections. More flexibility. • It is possible to speed up the drying process of sections of thickness from 20-30mm without any risk, in comparison to the other sections.

1 — 2

• For industrial production the second design was more economical.

The final prototype //

Explanation of concepts The wind gets separated and part of it resumes to move towards the top. The other (much smaller) part is redirected over te PV-panel by the means of an aluminum profile

The aluminum profile functions as a seperator of windstreams an manages the water distribution. The water gets captured in the small bucket shape of the aluminum. From there it falls into the ceramic elements.

The wind in the cavity has a high velocity and is directed towars the top of the building (due to chimney effect). 1 — 3

Wind from the outside can flow through the top and can not have a downwards direction (because of the ceramic and aluminum plate). If the wind flows to the bottom of the element (it gets splitst when the wind hits the top of the design) it joins the wind from the bottom element and goes with an upward direction into the cavity.

C°

The radiation income on the PV-panel is maximized. This creates a lot of output, but also leaves a high temperature on the surface. This is reduced by the convection and evaporation of the element. Giving an even higher output.

The ceramic element is saturated by the water dripping from the aluminum profile. The water is prevented from dripping downs by foam between the elements. This way the water has to be fully absorbed by the ceramics. Once saturated, the water flows over the bowl on the top and falls down to te element below.

The Final Prototype // Drawings of Details

The Axonometric view

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攀爀

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㄀㜀砀㌀㐀砀㈀

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㨀挀攀爀愀洀椀挀瀀椀攀挀攀琀礀瀀攀戀

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㨀猀漀氀椀搀猀琀攀攀氀瀀椀瀀攀㄀砀㠀

㨀猀琀攀攀氀䰀瀀爀漀漀氀攀㌀砀㌀砀㌀

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1 — 4

㄀㠀砀㄀㈀㠀砀㠀

㨀猀琀攀攀氀戀漀氀琀琀礀瀀攀䄀㄀砀㌀

㨀猀琀攀攀氀渀甀琀㘀砀㌀砀㐀

The axonometric view shows a detailed assembling strategy. This is used to assemble the prototype. The different components are numberd and refered to for the LCA later on in the paper.

The Final Prototype // Drawings of Details

The Assembly - Step by Step

1 — 5

The Final Prototype // Drawings of Details

Connection between Solar panels

1 — 6

1 — 7

1 — 8

1 — 9

1 — 10

05 | LIFE CYCLE ANALYSIS LIFE CYCLE ANALYSIS for a Deeper understanding of the material

In order to have a deeper understanding of the components; suitability & sustainability, the life cycle assessment is imperative.

1 — 11

Quantity

Box dimensions

156 x 96 x 28 mm

recyclebility

Material 25 % sawdust ( 12 % chammote ( 63 % clay (

Availability

Out of 5 stars

4,06 gr ) 39,5 gr ) 250 gr )

Price Lifespan Industrial (euro/kg) Years

downcycle -> cammote

Sawdust - +/-0.03 kaolin clay - 0.29 Chamotte - 0.09

Carbon footprint Kg/kg

estimate: 50-70

Sawdust kaolin clay Chamotte

0 (recyled) 0,028 0 (recycled)

1. CERAMIC PIECE TYPE A

Quantity

Box dimensions

156 x 96 x 28 mm

recyclebility

Material

Availability

Out of 5 stars

Natural rubber ( 0,00095 gr )

Price Lifespan Industrial (euro/kg) Years

downcycle renewable

1,31

Carbon footprint Kg/kg

estimate:+/- 30

1,86

2. NATURAL RUBBER

Quantity

Box dimensions

156 x 96 x 28 mm

recyclebility downcycle -> cammote

1 — 12

3. CERAMIC PIECE TYPE B

Material 25 % sawdust ( 12 % chammote ( 63 % clay (

Availability

Out of 5 stars

4,06 gr ) 39,5 gr ) 250 gr )

Price Lifespan Industrial (euro/kg) Years Sawdust - +/-0.03 kaolin clay - 0.29 Chamotte - 0.09

estimate: 50-70

Carbon footprint Kg/kg Sawdust kaolin clay Chamotte

0 (recyled) 0,028 0 (recycled)

Quantity 2x

Box dimensions mm

Material

180 x 128 x 8

recyclebility

Availability

Out of 5 stars

plywood - multiplex ( 4,06 gr )

Price Lifespan Industrial (euro/kg) Years

downcycle renewable (100%) biodegradable

0,492

Carbon footprint Kg/kg

estimate: 30 - 40

1,35

4. STEEL PROFILE

Quantity 8x

Box dimensions mm

Material

30 x 30 x 30

recyclebility

Availability

Out of 5 stars

Stainless Steel (austentic)

Price Lifespan Industrial (euro/kg) Years 2,12

Recycle (38% in current suply) Downcycle

Carbon footprint Kg/kg

estimate: +50

1,19

5. STEEL L PROFILE

Quantity 4x

Box dimensions mm

60 x 30 x 40

M12

Recycle (38% in current suply) Downcycle

—

6. STEEL NUT

Availability

Out of 5 stars

Stainless Steel (austentic)

(per box)

recyclebility

1 13

Material

Price Lifespan Industrial (euro/piece) Years 0,05

estimate: +50

Carbon footprint Kg/kg 1,19

Quantity

Box dimensions

17 x 34 x 2000

recyclebility

Availability

Out of 5 stars

“Brute” Aluminum (Cast)

Price Lifespan Carbon footprint Industrial (euro/kg) Years Kg/kg 3,95 estimate: 60 - 65 2,48

Recycle (43% in current suply) Downcycle

“LEKDORPEL”

Material

7a. METALLIC COMPONENT

Quantity

Box dimensions

10 x 20 x 2

recyclebility aluminum grey 1 x 1 cm

Material

Availability

Out of 5 stars

“Brute” Aluminum (Cast)

Price Lifespan Industrial (euro/kg) Years

Recycle (43% in current suply) Downcycle

2,12

Carbon footprint Kg/kg

estimate: 60 - 65

2,48

7B. METALLIC COMPONENT

Quantity 16x

Box dimensions mm

Recycle (38% in current suply) Downcycle 5.0x50 “rotadrill” torx screws

8. STEEL BOLT TYPE A 1 — 14

Availability

Out of 5 stars

Stainless Steel (galvinised)

5 x 50

recyclebility

Material

Price Lifespan Industrial (euro/piece) Years 0,03

estimate: +50

Carbon footprint Kg/kg 1,19

Quantity

Box dimensions mm

1000 x

Availability

Out of 5 stars

Stainless Steel (austentic)

recyclebility

Price Lifespan Industrial (euro/piece) Years 2,05 estimate: +50

Recycle (38% in current suply) Downcycle

9. SOLID STEEL PIPE

Material

Carbon footprint Kg/kg 1,19

FIS PROFI “Draadeind” M12 Verzinkt 1M 91202012

Quantity

Box dimensions mm

Availability

Out of 5 stars

6 x 2,5 x 4

4 recyclebility Costum made: “fake PV-holder”.

Material

Price Lifespan Industrial (euro/kg) Years 4,14

downcycle recycle (2,07% in current suply)

Carbon footprint Kg/kg

estimate: 15 - 18

0,08

10. METALLIC HOLDER

Quantity 8x

Box dimensions mm

Recycle (38% in current suply) Downcycle

1 — 15

Newlec M3 flathead

Availability

Out of 5 stars

Stainless Steel (galvinised)

10 x 3

recyclebility

11. STEEL BOLT TYPE B

Material

Price Lifespan Industrial (euro/piece) Years 0,04

estimate: +50

Carbon footprint Kg/kg 1,19

Quantity 8x

Quantity

Box dimensions mm

Box dimensions mm10

x 3

12. STEEL WASHER

Recycle (38% in current suply) Recycle (38% in current suply) Downcycle

Availability

Stainless Steel (galvinised)

Out of 5 stars

Stainless Steel (austentic)

(per box)

recyclebility

Availability Out of 5 stars

Material

60 x 30 x 40

recyclebility

DIN 433, M12

Material

Price Lifespan Industrial (euro/piece) Years Price Lifespan

Industrial (euro/piece)estimate: Years +50 0,04 0,08

Downcycle

Carbon footprint Kg/kg Carbon footprint

estimate: +50

Kg/kg 1,19

1,19

Newlec M3 flathead

This LCA is made by comparing many prices, materials, information from various sites, articles and shop. The information is therefor based upon the market conditions of 23rd december 2020. The validity of prices and lifespans can not be guaranteed. The sites that have been used on that date have been documented (see list below) https://www.bnvtools.nl/woodies-schroeven-5-0x50-verzinkt-t-25-deeldraad-2.html?source=googlebase&gclid=EAIaIQobChMIotCkz5qm7gIVzEiRBR1_EA7nEAQYASABEgKcZ_D_BwE

https://www.gamma.nl/assortiment/gamma-metaalschroef-m3-x-10mm-cilinderkop-verzinkt-20-stuks/p/B458149

https://www.made-in-china.com/products-search/hot-china-products/kaolin_price.html https://www.agmrc.org/commodities-products/biomass/sawdust#:~:text=As%20of%202010%2C%20sawdust%20was,%242%20to%20%246%20per%20pound. https://www.bnvtools.nl/woodies-schroeven-5-0x50-verzinkt-t-25-deeldraad-2.html?source=googlebase&gclid=EAIaIQobChMIotCkz5qm7gIVzEiRBR1_EA7nEAQYASABEgKcZ_D_BwE

https://www.gamma.nl/assortiment/gamma-metaalschroef-m3-x-10mm-cilinderkop-verzinkt-20-stuks/p/B458149

https://www.made-in-china.com/products-search/hot-china-products/kaolin_price.html https://www.kleinmetaalshop.nl/bevestigingsmaterialen/rvs-moeren/rvs-moeren-m12-per-50-stuks.html https://www.agmrc.org/commodities-products/biomass/sawdust#:~:text=As%20of%202010%2C%20sawdust%20was,%242%20to%20%246%20per%20pound. https://www.indiamart.com/proddetail/aluminum-angles-3615746197.html https://www.cambridge.org/core/journals/experimental-agriculture/article/abs/lifespan-of-rubber-cultivation-can-be-shortened-for-high-returns-a-financial-assessment-on-simulated-conditions-in-sri-lanka/45A93762EAD93CA2705650BA46DE49C4

http://www.blucher-marine.com/technical/stainless-steel/#:~:text=Stainless%20steel%20is%20a%20clean,expectancy%20of%20over%20fifty%20years.

https://diy.stackexchange.com/questions/84007/what-is-the-lifespan-of-plywood-as-roof-decking#:~:text=As%20plywood%20lasts%20about%2030,dry%2C%20it%20can%20last%20forever. https://www.kleinmetaalshop.nl/bevestigingsmaterialen/rvs-moeren/rvs-moeren-m12-per-50-stuks.html https://www.rvspaleis.nl/ringen/sluitring/din-125a/din-125a-[-]-a2/din-125a-[-]-a2-[-]-m12/125-2-12_50

https://www.indiamart.com/proddetail/aluminum-angles-3615746197.html https://www.aluminiumvakman.nl/hoekprofiel-aluminium-20x20x2-mm.html?source=googlebase&gclid=EAIaIQobChMIg5Xkieil7gIV7UeRBR16fg5IEAQYASABEgLkiPD_BwE https://3dprinterly.com/pla-vs-abs-vs-petg-vs-nylon/ https://diy.stackexchange.com/questions/84007/what-is-the-lifespan-of-plywood-as-roof-decking#:~:text=As%20plywood%20lasts%20about%2030,dry%2C%20it%20can%20last%20forever. https://www.rvspaleis.nl/ringen/sluitring/din-125a/din-125a-[-]-a2/din-125a-[-]-a2-[-]-m12/125-2-12_50

https://www.praxis.nl/badkamer-keuken-wonen/deuren/deurbenodigdheden/tochtwering/lekdorpel-aluminium-17x34mm-200cm/1650464?utm_campaign=shopping&utm_content=&utm_source=google&utm_medium=organic&utm_term Vidakis, N., Petousis, M., Maniadi, A., Koudoumas, E., Vairis, A., & Kechagias, J. (2020). Sustainable Additive Manufacturing: Mechanical Response of Acrylonitrile-Butadiene-Styrene over Multiple Recycling Processes. https://3dprinterly.com/pla-vs-abs-vs-petg-vs-nylon/ Sustainable Additive Manufacturing: Mechanical Response of Acrylonitrile-Butadiene-Styrene over Multiple Recycling Processes, 12(9), 3568. https://doi.org/10.3390/su12093568

https://www.alibaba.com/showroom/pla-3d-filament-bulk.html

—

1CES EduPack software, Granta Design Limited, Cambridge, UK, 2009 16Vidakis, N., Petousis, M., Maniadi, A., Koudoumas, E., Vairis, A., & Kechagias, J. (2020). Sustainable Additive Manufacturing: Mechanical Response of Acrylonitrile-Butadiene-Styrene over Multiple Recycling Processes. Sustainable Additive Manufacturing: Mechanical Response of Acrylonitrile-Butadiene-Styrene over Multiple Recycling Processes, 12(9), 3568. https://doi.org/10.3390/su12093568

The Final Prototype // Details

The final clipping system (advice from Lander Lander))

The fist part are the aluminum profiles. We where allowed to take 8 pieces home (the amount to hinge 3 prototypes). The ide is to fixate them into the wooden back structure. Normally these clippers are “clipped” on an alluminum profile stretching horizontally over the whole facade. For our prototype we did not have these rails, so we drilled holes in the clippers to drill them on the wooden back structure. 1 — 17

The next step uses a plate spring of aluminum. They come in various sizes and shapes. Mostly because this part can be seen from the outside. This is used to press the ceramic tiles to the outside. The constant pressure makes sure the tile does not rattle when conditions outside get worse. In our prototype we simply drilled it to the back structure, just like what would happen in a real situation.

Now everything is set for our section to be put in. The section is design in such a way that it can be easily set in. It is resting on the bottom part of the design. The clippers are very slim and therefor there needed to be a negative geometry in the ceramic that fitted that. Ceramic shrinks in the oven, leaving it hard to model it to such precision. We did it and it could be fitted inside the 2 clippers.

Now that the whole element can be inserted, we ran into a problem. We tested it with a concrete model first before putting in our (presious) newly made ceramic. The spring pushed the concrete to the front(wich is necessary on a bigger sized building). This created tension that toghether with the thin concrete broke the piece almost immediately. Our ceramic could not be inserted into this system since its strength is much lower than the one of concrete.

Due to the 2nd lockdown we needed to transport all our prototype material to Jens’s place. Here at least one person could continue to buildt the prototype. f.l.t.r: • Ceramic pieces • Concrete pieces in molds. • Wooden building structure (incl. old clipping system) • Old mdf side joints • Aluminum profiles from Lander.

We also recieved some modern components from Lander to see first hand what is currently used within buildings. • Edge flat colored spring • Regular flat spring • Newest aluminum top profile • Newest aluminum regular profile • Newest aluminum bottom profile

1 — 18

Own image: The broken concrete pieces. Proof that designed and regular clipping system would not suffice

The Final Prototype // Drawings of Details

The application on facade

1 — 19

1 — 20

1 — 21

1 — 22

1 — 23

06|the building weeks

from drawings to contruction to quarantine

Two weeks of rigourous construction and assembling of components cut short by the new COVID-19 restrictions!

1 — 1

Building weeks // Preparing the material

The Magic Mixture

Through Research and experimentation we had acquired the knowledge necessary to produce our final material. Through our building weeks we engaged in preparing the material and moulds. The material was a composition of Clay (powder state, to maximize the homogeneous mix of binders ), Chammotte ( large particles, the size will increase the gaps in the drying process ) and sawdust ( large particles). The binders aim to increase the porosity ratio in the ceramic pieces in the drying and kiln process

PREPARING THE MATERIAL

1 — 2

MEASURING

MIXING

CASTING

Building weeks //

Material preparation

PHASE 1

PHASE 2

UNPACKAGE SOLID CLAY CUT IN SECTIONS

1 — 3

PHASE 3

PHASE 4

CUT IN SMALLER SECTIONS

OVERNIGHT DRYING

CRUSH 60 KG OF DRY CLAY

Building weeks //

Measuring binders item chamote big particles white clay 01795 water saw dust

PHASE 2

Final prototype mixture characteristic % bake clay crush and reuse into the mix from the factory, binder with clay and chamote , especific mix hot Big particles

ORGANIZE MATERIAL

1 — 4

PHASE 1

gr 15% -

ml. volume Kiln 165

60% -

660

25% -

275

MEASURE BINDER PER VOLUME

absortion

900

23%

PHASE 1

MIX COMPONENT TOTAL VOL. 1100

Building weeks //

Mixing process PHASE 1

PHASE 2

PHASE 3

PREPARE MIX COMPONENT

POUR CONTENT

MIX BINDERS HOMOGENEOUSLY

PHASE 4

PHASE 5

PHASE 6

ADD PROGRESSIVELY WATER CONTENT

EXAMINE WATER COONTENT

MASH MIXTURE

SCAN ME

MASHING HAND PROCESS 1 — 5

HTTPS://YOUTU.BE/VH2AUVJX62A

Building weeks //

Molding Process Experimentation FINDING THE BEST PLASTER METHOD

IMPROVEMENT CONCLUSION

The moulding process was a precursor to making the prototypes. This step illustrated the importance of choosing the desired material for the plaster mould fabrication. The idea was to obtain fine edges in the mould which could be used for mass production.

During the thermoforming, the plastic bends around the model leading to curved edges. If another material apart from foeam is used, the process of removing the domel will be difficult.

During the buildings weeks, we made moulds with clay, Foam and Thermoforming plastic. After trial and error, Thermoforming plastic was a better solution than the rest. This is because the niches and surfaces were defined much evenly than the rest. After the thermoforming process, the shape obtained was set in a container, and the plaster mix was poured. During the thermoforming, the plastic bends around the model leading to curved edges. If another material apart from foeam is used, the process of removing the domel will be difficult.

RATIONALISATION OF MATERIAL Using clay and foam, the addition of boundaries in the plastic container aims to reduce the liquid volume. This material does not attach to the plaster mix due to the clay properties, helping to speed up the diecasting process.

PLASTER PREPARATION PROCESS

SCAN ME

PLASTER MIX PROCESS 1 — 6

HTTPS://YOUTU.BE/ JYNPANUWGVY

Building weeks //

Molding Process Improvement LEARNING PROCESS OF MOULDING METHODS The molding process aimed to follow the traditional production methods of plaster moulds. During the building weeks, the team focuses on developing this process due to the material’s moisture absorption properties. However, the restricted amount of time forces the team to create a new solution that does not involve plaster.

SCAN ME

DIECASTING PROCESS 1 — 7

HTTPS://YOUTU.BE/ TDJPTAVY_6Q

Building weeks //

Molding Process Decision MATERIAL DEPOSITION PROCESS

DIECASTING PROCESS

THE RESULT AFTER 24 HOURS OF THE DRYING PROCESS

HAND PROCESS

SCAN ME

MOLDING METHOD 1 — 8

HTTPS://YOUTU.BE/JA8NWZUATUO

Moulding // Experiments

Moulding Process TYPE 1: Plaster & Clay

•The edges were not clearly defined •The clay used in this step was raw clay and hence it could be deformed easily. •In order to extract the shape of the mould, the Clay had to be destroyed.

1 — 9

TYPE 2: Plaster & Foam

•The edges were not clearly defined. •The clay could not be released efficiently from the mould. •In order to extract the shape of the mould, the foam had to be destroyed.

TYPE 3: Plaster &Thermoforming

TYPE 4: Foam

•The edges were clearly defined. •The process was faster. •The process yielded slightly curved edges but it was easy to release the clay from the mould.

•The edges were clearly defined. •The process was the fastest. •The mould can be used multiple times with no waiting period.

Building weeks //

Kiln Process

KILN METHODOLOGY After a slow 18 hours kiln process, the mixture has proved to resist the moistures’ heat exchange effect. Due to a homogeneous component mix, the pieces guarantee an equal evaporation effect along with the ceramic. Thus, it prevents the tile from exploding or breaking in the oven. 1 — 10

Moreover, the cooling effect was an essential quality factor of the pieces. Therefore, after baking the samples at 900 degrees, the bach rests in the oven allowing a progressive cooldownstage.

03|LANDER

KERAMISCHE GEVELBEKLEDING

This Dutch company is specialised in Ceramic tile cladding of facades and attachment systems.

1 — 11

(Lander (n.d.)) Original Ceramic tile hinge construction idea.

contacting Lander that seemingly solved the problem we where facing

Own image of employer showing different structures

Learing about the ceramics market and demands as well as detials about connection systems

Own image of their stock

Own image of desired ‘aluminum on aluminum’ clippers

Discussing possible solutions to construct it to the facade

We where searching for a way to attach the ceramic pieces to the facade. We investigated some techniques through Christine Jette’s contacts, but we hadn’t found a right fit. In the faculty of architecture we ran into a building sample of a ceramic tile. We contacted the company (named Lander) and asked if they knew the matching hinging structure. They contacted very positively and we where invited to their company in Oosterhout. After a 3 hour trip we met Jan. Jan showed us around and told us what their company does. They do business in ceramic cladding (liquid). They would be the supplier of big facade tiles to very delicate housing cladding. He gave a tour through the company and showed what they where working on. After explaining the project and what we where searching for he showed the evolution of clipping systems. From aluminium back profiles to wooden back structures to differnet railing systems and all. He suggested a certain section profile which would fit inbetween 2 steel clipping rails which would hold the ceramic in its place. He was very kind and gave us the tile to take home as well as 8 clippers for our prototype. We did not know that in order for a ceramic facade to work we also needed a spring profile. That profile would provide constant pressure to the tile, pushing it outward. This makes sure the tile would not clatter and break during heavy winds. We took everything, also some principal detials, back to the faculty to be tested on our newly made sections. They would fit and we thought they could be ‘the’ solution to our hinging problem. 1 — 12

Own image whole desired system for ceramic - facade attachement

Providing us with needed component.

Own image of assembled ceramic facade structure

all

Postbus 200 4900 AE Oosterhout

Showing us asemble it all

how

Side joint evolution

building weeks original design with panel clippers. Used within buildings to clip cermic tiles to structure. Plastic or wooden component to hold pv-panel in place

1 — 13

post-building weeks solutions New constructive system. Clippers did not work, so a primitive design solution is executed after building weeks new design has to much material, but carries the weight of the pv-panel as well as the clay units.

future design Advanced post building week solution. The excess material is removed and material is added where there is a lot of stress. the system carries all that is designed.

58.21

180.34

171.06

Side joint Analysis

59.46

44.82

28.30

52.93

103.01

114.81

8.11

59.46 121.46

Post building weeks

Future design

designed as a planar surface, filled with material. This way we would make sure that the clay element wont break and that it will hold the pv-panel in place

The attachment of the pv-panel and the pieces could be optimized. from the str can be concluded which is surplus mate A possible new design is given. Showin material ass wel as a slimmer/more aest

58.13

The stress analysis from Diana shows us where the (extra) material is needed and where it can be removed. The compression and tension lines are sketched.

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The new stress anlysis looked similar to t This is because the stress follows the sam The construction on the ‘right’ side is nee in order to keep the pv-panel in place.

Side joint material & Calculations Some small hand calculations in order to dimensionize the preliminary design before moddeling. downward forces and tension within the element are then investigated. After the calculations, Diana is used to gain precise values for thension, compression and stress. Then EDUpack software is used Stage 1: Yield strength (elastic limit) (MPa) vs. to determine the materials that Young's modulus (GPa) are suited within the design limitations. The amount of thension it need to handle, as well as down- or recylebility. From this it can be concluded that Al-alloys are best suited for the design. Their stiffness is high enough. Low alloy steel could also be used.

Yield strength (elastic limit) (MPa)

ated

Cast Al-alloys

1000

Polycarbonate (PC) Polystyrene (PS) Paper and cardboard

100

0,1

0,01 1e-4

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Low alloy steel

0,001

0,01

0,1

Young's modulus (GPa)

100

1000

10000

Final Prototype

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Final Prototype

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Testing if evaporative cooling can cool down the PV panel

ON DATA I T UA L A

C°

(ABSORPTION -EVAPORATIVE C OO LIN G)

Evaluation Data

Create iteration

Comparing data

AR1B031 Research and innovations

Team: Dimitrios Ntoupas, Jens Slagter, Juan Cruz, Rhea Ishani, Stella Pavlidou

Tutor: Thaleia Konstantinou

ABSORPTION CAPACITY

Absorption: The set-up is used to test the absorption potential of the material. The material specifications are White Clay [Sibelco (01795)] Pine (large particle) sawdust – Chamotte (large particle) baked at 900 C and the recorded absorption potential is 24%. First, the dry weight of the piece is recorded (Fig 1). They are immersed in a tub of water for a period of 12 hours (Fig 2) The weight of the saturated piece was recorded (Fig 3).

Measure the weight of the ceramic piece dry

Overnight soak the ceramic piece (12 hours)

Measure the weight of the soaked ceramic piece

Reference list

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To optimise the efficiency of the PV panels through passive cooling system The efficiency of the PV panels decreases after they attain a temperature of 35 degrees. The study explored two complimentary methods of experiments to validate the potential of evaporative cooling .The first investigation was an in-site test located in an urban context with the 1:1 constructed prototype to monitor the evaporation potential of ceramic pieces saturated in water. The experiment uses 8 ceramic pieces each measuring 30 X 130 X 90 mm that are designed to have an angle of 45 degrees. This is optimised to receive maximum solar irradiance on the PV panel in the south façade. The simulations show that the facades in the south orientation receive the maximum heat gain.

• Molter, P., Fellner, J., Forth, K., & Chokha-Chian:, A. (2019). Adaptive Bricks Potentials of Evaporative Cooling In Brick Building Envelopes to Enhance Urban Microclimate Gevels. 21–32. •Wincontrol, A. M. R. (n.d.). AMR WinControl the software for all ALMEMO ® measuring instruments. 6–17.

B EVA

IN PORATIVE CO OL

Data Analysis & comparison: the iteration of data The dry weight of 8 ceramic pieces were recorded. The other set of 8 ceramic pieces were soaked in water. The two sets of ceramics were let out to dry at a constant temperature of 35 C. The surface temperature of the wet and dry pieces was recorded every 30 minutes using an infrared thermometer This experiment provide data to make comparison between iteration of dry and wet pieces to record different values for humidity, wind speed and surface temperature. (Molter et al., 2019). To set up the boundary conditions of the measurements, a software developed by Fraunhofer Institute was used.

WINDFLOW SIMULATION

10.

4 Experimental setup

5 Measure temperature hourly

CFD simulation

6 Measure the weight of the soaked ceramic

Evaporation: In-situ measurements are recorded to prove the evaporative cooling effect of irrigated prototypes. The objects were monitored on two different sunny days (06.11.2020 & 12.11.2020) from 9am till 5pm with a time step of 10 minutes. Two instruments Ahlborn Almemo system and Win Control V6 Software were used to parallelly record the weather data. The recorded weather data included: solar irradiation, Air temperature, wind speed and relative humidity.

07|LOOKING BACK.....

REFLECTIONS | would you do it all over again?

Reflecting on a unique Do-it-at-home project to kick our master studies off!

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Reflections // Contemplating

The Eureka moments 1. Finding a corelation between overheating of PV panels & efficiency 2. TERRACOTTA : A material to absorb water 3. Undestanding the ceramic Industry from Christen Jetten 4. DIY smoke tests to understand Fluid dynamics 5. Integration of all three concepts in one design : 3D PRINTED MODEL 6. Thermoforming as a suitable process to make final Moulds

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7. The Magic Mixture! Clay | Chamotte | Saw dust 8. SUCCESSFUL KILN PROCESS!! 9. SUCCESSFUL FUNCTIONING PROTOTYPE !!!!

Moulding // Experiments

Side joint - REWORKED Some small hand calculations in order to dimensionize the preliminary design before moddeling. downward forces and tension within the element are then investigated. After the calculations, Diana is used to gain precise values for thension, compression and stress. Then EDUpack software is used to determine the materials that are suited within the design limitations. The amount of thension it need to handle, as well as down- or recylebility.

Future design The attachment of the pv-panel and the ceramic pieces could be optimized. from the stress analysis can be concluded which is surplus material. A possible new design is given. Showing the eliminated material ass wel as a slimmer/more aesthetic design

The new stress anlysis looked similar to the old one. This is because the stress follows the same path. The construction on the ‘right’ side is needed in order to keep the pv-panel in place.

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From this it can be concluded that Al-alloys are best suited for the design. Their stiffness is high enough. Low alloy steel could also be used.

Reflections //

REFLECTION 1. Using terracotta to find new alternative of material innovation: We started the buckylab project with a shared interest in the use of terracotta. It is an aesthetically pleasing material with a long history. We wanted to explore this old fashioned beautiful material in combination with new techniques like solar panels. It felt like a puzzle piece falling in its place when we found out that ceramic could be a solution to a problem the solar panel was experiencing.

Further experimentation is required to determine the optimus wood specimen. Due to the sawdust recollection process that takes place at the workshop, the classification of the wood types is not possible. Due to the ignisious factor difference among the wood species, it is necessary to classify and identify the proper type for this process. In an ideal case, the specimen should slowly burn to increase the gap formation process. In our case, pine was the material used the most.

This gave us a lot of motivation exploring the world of ceramics and initiated the idea of creating a new clay component. 2. In terms of circularity Finding ways to use demolition and waste material from the construction industry to give more significance to the product, is a result of the research rather than an initial goal. According to (Juan et al., 2011), the analysis of demolition material in european Union shows that 54 % of the output comes from clay base materials including bricks, wall tiles and other ceramic products, followed by concrete with 12% of the total waste. The projects aimed to increase porosity in ceramic pieces using several binders. The results of the material experimentation shows the relevance of chamotte binders to increase absorption ratio. This component comes from a circular process of reusing ceramic materials. The cycle takes place once the ceramic is selected, processed and crushed to create different grain scales that serve for several purposes. In our case, the implementation of large chamotte particles created mixture gaps in the drying process of the clay mix.

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As a result of our literature research, the use of wood as a catalytic material to increase porosity in the kiln process is addressed by (Chemani & Chemani, 2013) and other several authors. In order to prove this concept, the team has set up variations of the material binders, using higher and lower quantities of sawdust. This material was obtained from the wood workshop of the faculty of architecture at TU Delft University. Despite the expectation, the result of the material experimentation shows that wood is not the main factor for porosity increment. On the contrary, the excessive use of this input comprises the cohesion of the mix in most of the cases. And therefore, decrease the quality of the mix for the kiln process. The results of the experimentation has shown that 25 % of sawdust is the limit for optimal cohesion properties of the mix. The raport shows that the middle piece contains a sample of 25% wood and (10%) chamotte. Followed by the middle piece, that has the same proportion of wood but higher chamotte quantity (15%). And finally, the piece on the right is the sample with higher sawdust (50%). The quality decrement of the last ceramic tile is significant compared to the rest of the group. Moreover, the absorption ratio between the optimal sample ( middle ) and the piece with higher wood particles shows an improvement of 1%. The conclusive results show that wood particles are not a major influence of porosity ratio.

3. The magic mixture Despite the time frame, we have developed a material that serves the purpose, increasing absorption ratio of ceramic facade product. And as a consequence, create a passive evaporation cooling effect. However, further research is required to first prove efficiency of the system in a realistic experiment set up. Second, measure the mechanical properties of the material. In this regard, despite the effort of creating samples for the testing process, due to laboratory restriction it was not possible to run a compression experiment that proved the viability of the product in a facade system. Additionally, the partial result achieved of absorption ratio of 24 % can be improved by adding other components to the mix. As in the previous state, wood particles are not decisive for absorption improvements. Therefore, further experimentation to recognize optimos composition is necessary. As well as, the identification of a mix that works along in tension and compressive stress and porosity proportion needs to be further evaluated. The initial results show considerably good qualities. However, Is necessary to set up an experiment to test the quality of the pieces in outdoor conditions. The monitor process every 3 months for a year period will show the consequences of moistures inside the material.

4. Christine Jetten The development of a material product along with the specialist was fundamental to understand the material properties. First, the analysis of the ceramic methods empower the development of innovation in the project. From the material understanding, the molecular reaction of the clay shows to the team a clear methodology of production. Thus, in the drying process, the principal of shrinking effect was used to increase porosity ratio. Second, mix reaction to the different production process was fundamental to reshape the initial design. As a consequence to this study, the progress analysis of the traditional methodologies of handcrafting increased the real application of the research. Most of the assumptions that as a student we had were incorrect. One example of this can be seen in the idea of geometry freedom by using liquid clay. In the initial stage, the group aims to create organic complex geometries using liquid methodologies. Further research showed the need of solid clay to guarantee homogeneous material mix. This learning process narrows down the options of the production process, the geometry shape, and the ideas of design. The funnel process of proposition and proof helps the team validate ideas. As architectects, we ignored the power that tradition brings to the design process. From day one, we wanted to create an organic complicated shape appealing to the eye. The reflection of the result shows us that leaving aside the aesthetics aspects help us to create a more efficient product. Moreover, the material reshapes the geometry itself. Following the process of traditional methods we are able to innovate. 5. The Urban heat Island effect: How our material can help? A very modern problem that gained a lot of attention over the years. The densification and the trapping of heat in cities influences biodiversity, increasing pollution and energy cost. The ceramic part of our project traps water for a longer period of time. It cools down the pv-panel and does not trap any heat inside the material. The ceramic is working as a water buffer for the city just like vegetation would do. This meaning our material would have a positive impact on the Urban heat Island effect. It has to be mentioned that the scale difference between one facade and a whole city is so big that the difference will not be noticed when applied to just one facade in a city. 6. An alternate system for provision of water: The drip irrigation system In the beginning of designing the water management system we discussed various things. We decided that because the BuckyLab project was about facades, we wanted to solve the problem in the facade itself. Any concepts about external waterbody or additional water supply towards the building were removed. However when reflecting the final product beyond the buckylab it has to be researched if an external waterbody or irrigation system would not be more effective and feasible. We thought of some ideas, but did not investigate their full potential. 1 — 5

Using an external water body would keep the ceramic at a constant saturation. This would allow the product to be used in countries that do not encounter regular rainfall. Right now the product is only effective in countries that experience high temperatures as well as regular rainfall. When an external water body is applied there is no need left for regular rain to keep the facade ‘cold’. This would broaden its employability. 7. Complete understanding of traditional methods to innovate The project became very focussed on ceramic exploration. This while having no complete understanding of its market, properties, history, application, makability ect. If we would gain more insight into the full spectrum surrounding ceramics we could innovate more. It is only by understanding traditional methods that new techniques can be developed. When looking back we are very thankful to Christine for helping us. However, when continuing down this path of ceramics we need to develop more understanding of the material. This can not be done over the course of a few weeks, but by creating this new material we showed that there is room for innovation in the world of ceramics. 8. Variation of the prototype in different locations When designing the prototype for South India we tried to have as much parametric values as possible. However this was not reached to the full extend since it required knowledge far beyond the scope of the BuckyLab course. It is still valid to be implemented in the different parts of the world. It would raise the value of the product. The main goal is to only insert a 3dm site location and that the software gives (after extensive calculations) the best suited dimensions of the design. This includes different sizes and dimensions for each section that makes up the panel. The concept is based upon having unique sections (so each building would have its own unique element) but the facade is built up out of the same ‘elements’. This means that one extrusion mold is still used a decent amount of time before a different extrusion mold is needed for a different building. This concept could not be investigated further due to time limitations and the obstacles encountered when generating the full script. If the amount of details and the precision described in our report was going to be implemented in the script, a very strong computer or a series of servers is needed to come up with this amount of computational power. When we could eliminate some variables (because they are less significant on the power output of the solar panel) we can simplify the script. This would increase the chances of inserting our through-out product world.

9. CFD simulations The use of CFD simulations is very precise and required a lot of time to comprehend. Learning this new software is a good skill to gain, but the results could have been obtained faster. Halfway through learning how to use CFD and trying various software. We learned that it could also be done in a more practical way, with a smoke machine. This gave us a new perspective not only in experimenting with wind, but with how to experiment and how precise the results have to be in order to draw a conclusion. To visualize where the smoke was going was just as useful as the CFD simulation. Only the smoke machine tests only took a few hours. This can be used in other methods as well. When something takes too much time, you might have to look for another “easier” way. 10. The ceramic design The design that we made for the prototype is promising, however more improvements have to be made. After testing and validating, some systems didn’t work as efficiently as predicted. This is because the geometry had to be simplified and simplified in order to be able to mold it. Every time the design was simplified, it was harder to keep the effectiveness of the systems. This can be seen in how previous prototypes handled the smoke machine test versus the final design. However a solution can be provided. The design is based upon sections and a certain scale. Both of them can be adapted in order to make it more effective. The sections only consist of 2 different designs. When this is changed to making each piece unique, some design freedom is gained. Allowing us to be able to mold the pieces individually and still design some complex shapes. The scale of the project was determined by the 25 kg weight limit on construction sites. When this limitation was set up (by ourselves) we still treated the design as one whole element instead of several smaller ones. Now when we are many evolutions further, the design limit of 25kg is only restricted to one section. Allowing the size of the panel to be different. This change in size can reduce airflow and increase the amount of water that gets absorbed. 11. The Aluminum unit Due to the fact that we cannot make aluminum profiles within the scope of this project, we had to make one ourselves. This is done by combining several simple profiles to one ‘complex’ one. Aluminium cannot be soldered and the profiles were too thin to be bolted together. It is now done by using a silicon kit. However may our reflection state that: “this non-detailed aluminum profile influences the effectiveness of the designed systems.”. In order to see the full effectiveness of the systems, a custom made, one piece, of aluminum should be made. This to maintain precision (details needed to be 1 smaller than 2mm) and to gain strength (now it is influenced by windforce). 6

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Making just one unit would be expensive, but ordering many would make it cheap. Since every element of combined ceramics should have one aluminum profile, we would need hundreds for just one facade. Making custom made pieces of aluminum available. 12. Overall timeline and deadlines Looking back we did not have a very systematic process. You can say that our own indecisiveness led to many time-wise problems. We conducted a lot (and thorough) research. Then when it came to designing and taking research into practice we took a lot of time. We wanted to make sure to incorporate every little piece that we thought of was used in the design. In other words: we wanted the design to be perfect in the first try. Because of this we did not feel comfortable to run with one option, but rather keep redesigning until it captures the full scope of our ideas. Because of this it took a long time before our first real (agreed by everyone) design was constructed. By now we were already 2 weeks behind schedule. We could not generate the final drawing before the building weeks were planned. We had to measure everything last minute and make profiles and joints by just tracing one geometry (we did not define dimensions). When everything needed to be assembled, it did not perfectly fit. A lot of remaking, filing, redrilling and redoing was needed. Luckily we had the time for doing so because of the christmas holiday. 13. Industrialization : Extrusion V/s Hydraulic process Initially the production process considered for the project was focused on the development of complex geometries of ceramic components. The parametrization of clay elements to produce with regard to cooling effect aimed to add new functionalities to the shape. The 3D printing technology with 6 axis robots allows the building industry to incorporate new design purposes. As an example, the advanced ceramics R&D Lab has developed several prototypes of small and specific capabilities (Cruz et al., 2020). Including a masonry component, produced by the combination of computational design and additive manufacturing, to explore the capabilities of heat flow conductivity and superior structural performance. Despite the mentioned benefits, The reflection of Industrialization and production scalability, as well as, requirements for material binders forced the team to think on simpler strategies. As a result of this reflection, the geometry is based on a profile that allows the prototype to be industrialized using the process of extrusion. Therefore, the continuous extrusion of the material provides the clay beams to be segmented in small sections. This clay segmentation reduces the timeframe for the drying process, and decreases the risk of failure in the kiln stage.

Reflections //

Things that saved this project

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Reflections //

INDIVIDUAL REFLECTION

During the course I learned a lot about various things. New software, broadened and extended my grasshopper skills and changed my perfection list perspective into a more practical approach. However looking back on the project I could have done things differently. My communication skills are not on top, with COVID-19 this became more clearly. This resulted in non-understanding communication problems and some arguments about basic principles. I believe that communication is even more important now than ever. This is something I really learned from this course and its groupwork. The different personalities and approaches did not always level out, in combination with strong opinions and difficult communication resulted in some fierce arguments. Of course this was resolved and I believe strong arguments and different opinions are a necessity in order to create the most optimal (just like our project) result. When looking back we can see that we have vary different fields of interest and started with different skills. I believe we could have learned more from each other. It is unclear to me whether or not this is a direct result from the ‘working-at-home’ situation.

JUAN

Despite the quarantine limitations, the possibilities that the industry offers to the students was an unexpected outcome from this exercise. Several groups follow the same dynamic, using the support of the industry to develop a proof of concepts prototype. I enjoyed The Bucky lab design course, as it encouraged students to seek constant curiosity to develop innovative ideas. Unfortunately, the coordination of the course along the semester did not work with the study plan. I expected the lecture of Bucky lab engineering to work in cooperation with the design studio to learn and apply technical concepts. Insted, this class was an overwhelming time consuming video playlist that did not have any relation with the topics worked in the projects. In spite of this situation, the design project was an incredible adventure, having the possibility to visit specialists, factories and artists involved in the ceramic industry was an incredible opportunity. Working closely with Christine Jetten, showed me the potential of clay base materials for further research. Moreover, working with people that show diverse interests and perspectives served to create a project that tackles from technical to aesthetic aspects. Thanks to Nadie and Marcel the communication channel was clear.

JENS

DIMITRIOS

Buckylab for me is the course that forced me to think outside the box and understand how the different fields in Building Technology are interrelated. Our concept PHOTOCERAMICS demanded a lot of focus on experimenting with materials before the design phase. The fact of digital meetings though, made some practical manners more difficult. We could not sketch and show instantly our ideas, like we did before the pandemic and for that reason we reached the design phase later than we expected. Nevertheless, through this, I learned several aspects of how a successful collaboration can be reached. Even if we made a long journey with our concept there are a lot things that could potentially be optimized such as the wind flow mechanism, which changed a lot during the design phase. However, I feel enthusiastic about PHOTOCERAMICS and I am sure that there is a real spark in that project that can create groundbreaking innovations in the future. Building Weeks were the best weeks of the whole quarter. A main reason is that we had taken most of the exams and we did not have any close deadline. What is more, I believe that Research and Innovation was really successfully integrated in Buckylab design in contrast to Buckylab engineering.

RHEA

Cycling to the Faculty, every tuesday to meet Marcel, Nadia and my other classmates was the highlight of every week for the last six months. The Bucky Lab as a course was very well structured and was successful in providing a glimpse of what the Graduation thesis would be like! Through this project, I got to learn from my team members and also collaborate with Artist Christen Jetten, who helped us realise our prototype. However, as an international student I found it difficult as I did not get a chance to apply the knowledge I gained from the Engineering Courses, in order to fully understand the practical side. The structure & schedule of Engineering courses gave me an impression of a ‘race’ that I had to run for months to be able to finish them! Due to the pandemic, I missed the hands-on workshop sessions, which would help me learn more about PV, than relying completely on online sources, even in the presence of experts. In conclusion, I feel that Buckylab design has benefited me as an architect majorly. Through experimenting and through research by design I gained knowledge about many fields in such a difficult period of time. I am satisfied with our final result and even if there were numerous challenges to tackle through the quarter I feel really lucky that I study here and I am looking forward to the next courses.

STELLA

Being a member of a large group has both advantages and disadvantages. Decisions take longer to be made; however, the quality of the final project is higher. As a student I was lucky to be part of a talented team and I learnt a lot from my team members. My team consisted of people with diverse qualifications and that contributed to a good result. Due to coronavirus interaction was hard and the actual working time in the faculty felt insufficient. Also, throughout the quarter, I felt overwhelmed by the demands of courses like Bucky Lab Engineering and I had to sacrifice time from Bucky lab design to keep up with the demands of courses like Building Physics. I wish I had more time to be creative and produce ideas, unfortunately the workload did not allow me to do so. Also, I missed hands on work, like working with actual PV’s and also fabrication during building weeks which I know was due to the virus. As a final thought, I have to admit that during the quarter we changed a lot our design and looking back it was fun to learn from our mistakes, so thank you both Nadia and Marcel for allowing us to learn from trying.

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Many thanks to you, Marcel & Nadia, for a successful Bucky Lab Studio!

Group IV | Bucky Lab | 2020

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References //

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