AA Int13 2017/18_MULTI MATERIAL

MultiMaterial

Dalal Itani INT 13 / 3rd Year / Design Project

intro

Metal

/

Wood

/

Powder

/

Elastic

Materials

/

Resin

/

Glass

/

Ceramics

^ NASA flexible metal

^ Adidas - 3D printed soles

^ Zaha Hadid - multiproperty 3D printed chair

^ ARUP - metal 3D print

^ Iris Van Herpen - 3D printed dress

^ Stratasys - multimaterial print

3D Printing in numbers

State of 3D Printing (2017) survey by Sculpteo

AM technologies represent a significant opportunity to develop products that previously could not be manufactured,

an opportunity to make existing products better, and to customise products to specific needs.

A central characteristic of traditional manufacturing is

indeed absent in AM processes, which provides strong em-

pirical evidence for one of the key claims underpinning

the economics of AM technology: variety can be produced at zero marginal cost.

3D printer

Country

B

Erectorbot EB 2076 LX

United States

6

THE BOX

Sweden

1

Tractus3D T3500

Netherlands

1

CoLiDo Mega

China

1

DeltaWASP 3MT

Italy

3

3D Platform 400 Series

United States

Titan Robotics Atlas 2.0

United States

BigRep ONE

Germany

1

Fouche 3D Printing Cheetah Pro

South Africa

1

Moebyus Machines M3

Spain

1

HORI Z1000

China

1

Extreme Builder 2000

Netherlands

Zilla3D Deltazilla

United States

Leapfrog XceL

Netherlands

German RepRap X1000

Germany

The 15 largest 3D

This selection of large volume 3D printe *MSRP: Manufacturer su

Price (MSRP*)

6096 x 2133 x 1829

Build volume (m³) 23.78

1500 x 1100 x 1500

2.48

< $250,000

1000 x 1000 x 2000

2.00

€34,500

1000 x 1000 x 1500

1.50

$26,000

3000 x 3000 x 3000

1.20

€22,400

1000 x 1500 x 700

1.05

$36,999

915 x 915 x 1220

1.02

$26,200

1005 x 1005 x 1005

1.02

$10,000 - $50,000

1000 x 1000 x 1000

1.00

$10,400

1000 x 1000 x 1000

1.00

€14,995

1000 x 1000 x 1000

1.00

$40,000

700 x 700 x 1820

0.89

€18,995

750 x 750 x 1220

0.69

$7,995

510 x 500 x 2300

0.59

€22,499

1000 x 800 x 600

0.48

$65,500

Build size (mm)

printers in 2018

ers is based on decreasing build volume. uggested retail price.

$46,425

Architecture &

3D printed concrete house by Apis Cor / San Francisco ( 2017 )

3D printed office by WinSun Global / Dubai ( 2016 )

& 3D Printing

WinSun Decoration Design Engineering Co, 3D printed buildings, China

Mobile Robots & 3D Printing

Stone Spray Robot by Anna Kulik, Inder Shergill and Petr Novikov

Anti-gravity 3D printer by Petr Novikov and SaĹĄa JokiÄ&#x2021;

Flight Assembled Architecture by ETH

Robot 3D Printed metal bridge by MX3D

Visual Inspiration: natural cellular structures

Case Study: Glass Sponge Structural System

Hexactinellid sponges are known for their ability to synthesize unusually long and highly flexible fibrous spicules, which serve as the building blocks of their skeletal systems.

These spicules consist of a central core of monolithic hydrated silica, surrounded by alternating layers of hydrated silica and organic material.

Following loading, fracture of this laminated structure involves cracking of the constituent silica and crack deflection through. the intervening thin organic layers, leading to a distinctive stair step-like fracture pattern.

Dimensions: cylinder diameter: bottom 2-3cm. top 3-5cm. cylinder length: 20-30cm number of horizontal struts: 60-80 number of vertical struts: 20-30

Formation of the underlying quadrate skeletal lattice from non-planar cruciform spicules

Description: square lattice composed of a series of over lapping vertical and horizontal fibrous struts.

Configuration: a network of non planar cruciform (stauractine) spicules. the horizontal rays of these spicules overlap with those from a neighbouring one and assemble to form the ring-like structures. The quadrate skeletal lattice is itself composed of two overlapping grid systems a+b.

Dimensions: rays diameter: 0.08-0.1mm V. rays: 10mm H. rays: 5mm H. rays angle from x-axis: 10° V. rays angle from z-axis: 0° Role: base grid for the synthesis of the skeletal lattice.

Diagonal spicule bundles

Description: diagonal spicule bundles overlapping the base grid Configuration: an additional set of orthogonal bundled spicules struts, oriented diagonally (at approx. 45° to the cylinder axis) and surrounding the tube in oblique spirals. By offsetting the diagonals from the nodes, roughly octagonal openings are formed, creating a series of alternating open and closed cells (checkerboard pattern).

Dimensions: spicules diameter: 0.005-0.05mm spicules length: variable bundled struts diameter: 0.2-0.5mm Role: diagonal bracings are essential for supporting bending, shear, and torsional loads exerted on the skeletal lattice.

Holdfast appartus

Description: bundles of long fibrillar spicules superimposed on the reinforced quadrate skeletal lattice in the lower region of the sponge skeleton.

Configuration: the holdfast appartus is composed of about 2000 spicules. Each of these has a smooth distal and a barbed proximal refion that is terminated by an apical spinous process.

Dimensions: anchor in the sea floor, terminating at approximately 1/3 of sponge height.

Role: branching system to optimise anchorage in the sea floor whilst supporting load of the structure.

Terminal sieve plate and its lateral egde border

Description: border: dislinquished from the other ridges by being thinner, and typically possessing sharper edges not in direct connection with the rest of the ridge system. plate: irregular cellular network capping the open cylinder.

Configuration: plate: the structure results from the incorportation of a wide rnage of morphologically distinct spicules: diactines (2-rays), tetracine (4-rays) and hexactine (6-rays) forms.

Dimensions: variable Role: protecting the sponge interior, preventing from lateral collapse of the top of the skeletal lattice, increase in strength and stiffness.

Wood

Plastic

2D cell analysis

In mathematics, a Voronoi diagram is a partitioning of a plane into regions based on distance to points in a specific subset of the plane. That set of points (called seeds, sites, or generators) is specified beforehand, and for each seed there is a corresponding region consisting of all points closer to that seed than to any other. These regions are called Voronoi cells. The Voronoi diagram of a set of points is dual to its Delaunay triangulation (In mathematics and computational geometry, a Delaunay triangulation (also known as a Delone triangulation) for a given set P of discrete points in a plane is a triangulation DT(P) such that no point in P is inside the circumcircle of any triangle in DT(P)).

Benefits and potential of the cellular arrangment : a ) growth b ) exchange c)

rearrangement

Individual

scale: 3 m

Commu

unal

Clusters

Voxel8â&#x20AC;&#x2122;s 3D printer integrates polymer and electronic components in a single print.

Dual-extrusion 3D Printer by Ultimaker.

Strata

asysâ&#x20AC;&#x2122; Object500 multimaterial printer using triple-jetting technology.

Stratasys material availability and selection.

Multi - Material Printing

Curtain wall detail (2015) by Kostas Grigoriadis

Semi-Rigid Car by Tom Wiscombe

Vespers by Neri Oxman

Fuzzy Structures by Jim Peraino

Mixed Matters

The Epistemology of Designing with Functionally Graded Materials

by Kostas Grigoriadis

Multi-material design is a process mainly concerned with the assigning of gradients between two or more dissimilar materials, as well as their extents. Particle system elements are by virtue of their computational structure made to simulate natural phenomena and effectively the behaviour of materials. Particle simulations have therefore been utilised as a design tool and in order to allow for the gradients to be computationally calculated based on the physical material properties of the substances to be fused.

Exploded multi-material curtain wall detail showing constituent material composition (2015)

In contrast to composites, which are effectively laminates, functionally graded materials (FGM) are singular multi-materials that vary their consistency gradually over their volume. As their use is expected to become increasingly prevalent in fabrication and construction, the research explores a future where â&#x20AC;&#x2DC;trueâ&#x20AC;&#x2122; continuity will eventually be enabled in architecture through the merging of different materials that will be fused together three-dimensionally. The specific focus in this context is to propose a revised design methodology that corresponds to these changes in building technique, repositioning material behaviour as an integral and defining part of the design process. The anticipated outcome of the thesis is a new design manual that defines a procedure that can be followed in order to design continuously graded material constructs.

Constituent material composition detail (2015)

Es Devlin - scent infused mirror

Zuza Mengham f

Asif Khan - VantaBlack Pavillion

The Smell

for Sculpting Scent

of Data Frangrance

Fernando Mastrangelo - Escape Furniture

Es Devlin - VR Therapy

Resin - Late

ex - Plaster

Design Proposal

3D Printing modular system that extends or plug into an existing structure

Serpentine Sackler Gallery, Zaha Hadid

Michael Lee-Chin Crystal, Royal

Ontario Museum in Toronto

Antwerp Port House, Zaha Hadid

SITE : BEIRUT

Beirut is one of the most densely populated cities in the world.

Although no proper census has been conducted in Lebanon since 1932, the United Nations puts Beirut's population at 470,000, not including the suburbs. In a city that covers just 85 square kilometers, space is tight. The result is an incredibly intense architectural mix. Gleaming towers pop up in the backyards of treasures from the Ottoman Empire and the French Mandate for Lebanon, which lasted from 1923 until the mid-1940s.

Most of Beirut's old buildings have already been lost to war. But today, the Lebanese capital's remaining architectural heritage is up against a new enemy: developers. Demolition of old buildings is a daily occurrence in Beirut, where high-rise flats and car parks are taking over the city.

In 1995, then-Minister of Culture Michel EddĂŠ managed to halt the demolition of over a thousand old residences thanks to the recommendations of the Association for Protecting Natural Sites and Old Buildings in Lebanon (APSAD).

Unfortunately, this decision also sparked a fresh wave of demolitions, as owners who became concerned about further government regulation had their properties razed in order to be able to sell the land on to housing developers.

In response, the government went against the recommendations of APSAD and declassifying around half of the old buildings that were meant to be listed as protected. By 1998, that number was halved again, leaving just 209 buildings out of the original 1016 safe from the risk of demolition.

In 2007, the Lebanese government proposed putting forward a law to save the endangered buildings, but this has not yet been addressed. Nevertheless, a number of associations are now campaigning for the law to be passed.

The Green Line

Beirut as a battleground

Survey of war damaged buldings in Beirut

Beit Beirut

Beit Beirut is located in the heart of Beirut along Damascus road on Sodeco Crossing, along what used to be the “green line”, the line of separation of both parts of Beirut during the Lebanese war that started in 1975.

Originally a residential building built by the Barakat family with two imminent architects of the thirties “Youssef Aftimos” and “Fouad Kozah”, the building has great architecture values representing the start of modernity in Beirut in the style known as the”Yellow Houses”.

Occupied by snipers during the war period, the building kept all the war traces, scars, and installations. It was used as a snipers den for over 15 years, like many buildings along the green line.

The building was expropriated by Beirut Municipality in 2003 in order to be transformed into a museum and a cultural center dedicated to the memory of the city of Beirut. The architect Youssef Haidar was designated to program the future use and design the museum and architectural project, along with all the construction supervision works.

Site Plan

us

sc ma Da et

re

St

t

nce S tree

Indep enda Independance Street

N 10 m Green Line

Side Elevations

Isonometric view of site in relation to surroundings

Sunset

Sunrise

Midday

Sun position in relation to site

N 50m

Collage

Glass

Adhesive

Gradual Clay Frame

Recycled Sandstone

Original Sandstone

Case Study: Glass House by Herzog & De Meuron

A novel glass masonry façade has been designed and engineered to replace the brick façade of a former townhouse in Amsterdam, aiming to preserve the city’s traditional architectural style and historical ensemble. Designed by the MVRDV architectural studio, the innovative façade follows the original nineteenth century elevation down to the layering of the bricks and the details of the window frames, but is stretched vertically to comply with updated zoning laws and allow for increased interior space (MVRDV Architects 2016).

Based on the brick modules of the original masonry façade, the 10 by 12 m transparent elevation employs more than 6500 solid glass bricks, each 210(±1)mm thick by 65(±0.25)mm high, reinterpreting the traditional brickwork and the characteristic architraves above the openings; while massive cast glass elements reproduce the classic timber door and window frames. As it ascends, terracotta bricks intermingle with glass ones, gradually transforming the glass elevation to the traditional brick façade of the upper floor. The architects’ desire for unimpeded transparency excluded the use of a metal substructure, rendering the choice for an entirely self-supporting glass brick system as a necessary and so far unique solution.

An entirely transparent structural system is obtained by bonding the glass bricks together with a clear adhesive. In the developed system, the mechanical properties of this adhesive are equally critical to the ones of the glass blocks; it is their interaction as one structural unit that defines the systemâ&#x20AC;&#x2122;s structural capacity and behaviour. The most favourable structural performance is when adhesive and glass bricks fully cooperate and the masonry wall behaves as a single rigid unit under loading, resulting in a homogeneous load distribution.

Principle of the proposed structural glass system

Practical implications encountered when combining terracotta and glass blocks, such as differences in acceptable tolerances and in use of adhesives

Bonding of the ceramic strips to the shorter bricks

The final visual result after the ceramic strips have been sealed

To obtain a smooth, gradual connection to the standard brickwork of the final, residential floor of the building, the initial intention of the architects was to realize a transition zone of intermixing glass and normal terracotta bricks towards the top of the faรงade. Nonetheless, the structural blend of the two materials presented various practical implications. Besides having different mechanical properties, the two types of bricks vary remarkably in acceptable tolerances. Most importantly the bonding between the two brick types necessitated different types of adhesives which could damage the glass bricks.

Due to all the aforementioned reasons, the option of combining terracotta and glass was discarded.

Instead the following solution was applied: Glass bricks, 40 mm shorter in width, clad with an 18 mm thick ceramic strip at each external side, replace the traditional bricks in the intermixing zone. The ceramic strips are bonded on the faรงade after all glass blocks have been bonded in place, preventing the occurrence of adhesive stains on their exterior surface.