FUNICULAR CLAY SHINGLES Clay Shingles Pavilion in Camden Market
Tutors: Daniel Widrig Guan Lee Soomeen Hahm Stefan Bassing Igor Pantic Adam Holloway TeAM members: Hao Li Wenyan Zhao Jialin Tang Xinnan Zhao Zizhuo Su Heyoung Um Jiawei Xi Xiangheng Min
CLAY ROBOTICS INTRODUCTION HAO LI, XIANGHENG MIN, JIALIN TANG, ZIZHUO SU,
HEYOUNG UM, JIAWEI XI, WENYAN ZHAO, XINNAN ZHAO Clay has been a widely used material for centuries as it is easily available, cheap, and plastic in application. This is especially true when clay is used in digital fabrication, as the digital extruding process makes non-standard designs possible to fabricate in a relatively easy and quick manner. This shows the potential and ability for mass customization or “quick-prototypes”. Industrial robotic arms have been widely used in architecture for many years, and work has been undertaken exploring the possibilities of automated fabrication in highly efficient and innovative ways in order to discover the potential of the materials in digital fabrication. When clay meets the robotic arm, the interaction between them is unstoppable. The robotic arm at Grymsdyke Farm is a KUKA KR210, which can move in 6 different axes. However, at the present time, ceramic printing is always printed layer by layer; the extruder is basically used only perpendicular to the platform. The robotic arm has therefore not been taken full advantage of. Testing, designing, and printing ceramic components in ways that go beyond the layer technique is therefore the main subject of this study. One of the fabrication modes in which they are used is large-scale 3D printing. However, due to the limitations of the equipment, techniques, and materials, industrial robotic arm clay printing has remained relatively stagnant. Due to the innovation in robotic arm clay
printing, the projects this year have been achieved by the use of “Space” clay printing with support. Clay could never be produced in as quick and solid in a way using existing technology, so the aim became to control the robotic arm to facilitate printing along with the support, letting the nozzle climb on the surface. An analogy for this would be people walking on the earth, who would always be drawn toward the centre of the earth due to the gravity. With this technique, a shell-shaped component could be achieved. Thus, the robotic arm could be used to work in a freer way, and instead of relying on layer-by-layer texturing, other textures could be introduced. This year, the group has four projects, including V&A Tiles, Funicular Clay Shingles, Catenoid Aggregates and Manifold Assemblies. For the V&A Museum project, more than 2000 tiles are produced by robotic arm, which is the first mass digital fabrication of clay. The Funicular Clay Shingles form the baseis for the following two projects. As for the Manifold Assemblies, the tridimensional clay components are combined with wood frame and fabricated by the method of CNC carving and slip casting. And the fourth one is printed by robotic technique to realize the actual 3D clay printing. With the development of the technique innovated, this group achieved the clay application and digital fabrication in the actual construction.
TABLE OF CONTENTS
01 UNDER BRIDGE ARCH > SITE INTRODUCTION > FORM DESIGN > COMPONENT
02 CLAY EXTRUDING PAVILION > form finding > subdivision > structure > component > texture research
03 CAMDEN MARKET > site Introduction > form design
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UNDER BRIDGE ARCH > Site Introduction > Form Design >Component
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UNDER BRIDGE ARCH [Site Introduction]
Site Analysis This site is locatted in the east side of the camden market, which is still under construction. The red line showing in the map is the cave where we will put our intallation. The cave under the railway is a special part of the camden market. A lot of shops and art works are locatted in the caves. So, the caves in the market is not only the walking path through the two site parts, it is also an attraction of the market.
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UNDER BRIDGE ARCH [Form Design]
Reference
Antelope Canyon was formed by erosion of Navajo Sandstone, primarily due to flash flooding and secondarily due to other sub-aerial processes. Rainwater, especially during monsoon season, runs into the extensive basin above the slot canyon sections, picking up speed and sand as it rushes into the narrow passageways. This project is located in a cave a little bit like standing in a place like Antelope Canyon.
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The shadow caused by the contrast between light and darkness is always fantasy and full of interesting. It is flexible due to the differnt shapes of the holes of the component. Because the site is in the cave, so the environment is always dark. So with the light and shadows, it will become more attracting. People from differnt palce would more like to find this place.
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UNDER BRIDGE ARCH [Form Design]
Design Analysis
Straight path
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Enrich the path
Simulate the Antalope Canyon
Simu Antalop
ulate the pe Canyon
Curve Wall
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The curve wall need to be subdivided into small component. The wall is about 6-7 m long and 1 m high. So if each compnonent is 0.5 square meter. We need about 35 pecies.
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UNDER BRIDGE ARCH [Form Design]
Minimal Surface Prototype We design several differnt kind of minimal surfaces through computer program. Each component is in a different shape and the looks different in various views. When they attach with each other, more interesting shapes and textrues would be created. But still they are hard to fabricate, and no one did this kind of component by printing clay. So, it would be a real challenge .
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UNDER BRIDGE ARCH [Form Design]
Assembling Prototype
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When the component connects with each other, it will showing different types of textures. And also different holes will show different shadows when the light go through. But because the minimal surface is based on the square shape, so the shape is always linear and angular. This is a problem when applying these component into the curve wall.
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UNDER BRIDGE ARCH [Form Design]
Assembling Test This surface or so called wall will be subdivided into several parts. We try to subdivide the wall with minimal surface component. Each component will attach with each other. But when we test in the computer program, we find that minimal surface component is not suitable for the curve because the component is based on the sqaure shape. So, these componet deform when they are using for assembling the curve wall, which is not good for digital fabrication. Each component is different, and hard to acheive complex shapes.
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VS curve surface
Minimal surface
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UNDER BRIDGE ARCH [Form Design]
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CLAY EXTRUDING PAVILION > Form Finding > Subdivision > Structure > Component > Texture Research
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CLAY EXTRUDING PAVILION [Introduction]
Introduction
After participating in the designing of camden market, we recognized the disadvantages of our design and some of them cannot be ignored and we may start again. Basically, it is very difficult for us sovle the problem about supporting the clay components by the components themselves with our exsiting facilities. Furthermore, it is hard for us to guarantee the safety of the people who stand under the pavilion we made by clay. Therefore, designing a stable structure is an inavoidable thing we would meet in next term. Nowadays, our task is finding out some possibilities about shapes and structures, some references are necessary for us to explore a new area of imagination. The shape we would choose should not be too complicated because the most important point is displaying a pavilion with the character of clay and the relationship between environment and material. The grasshopper plugin named kangraroo is a good way to design a pavilion corresponding principle of mechanics. It is relatively logical to build a pavilion by this sort of design and relatively easy to save our energy and time. Therefore, we tried to design some shapes with this plugin and to abide by logic of mechanics.
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Reference
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CLAY EXTRUDING PAVILION [Form Finding]
Form Finding 1
Top
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Front
Perspective
Marine oganisms always be source of artists' inspiration. For displaying our components attached on the structure as much as possible, we would like to choose a stretch shape like a shell. A shell is a type of structural element which is characterized by its geometry, being a three-dimensional solid whose thickness is very small when compared with other dimensions, and in structural terms, by the stress resultants calculated in the middle plane displaying components which are both coplanar and normal to the surface. Essentially, a shell can be derived from a plate by two means: by initially forming the middle surface as a singly or doubly curved surface, and by applying loads which are coplanar to a plate's plane which generate significant stresses.
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CLAY EXTRUDING PAVILION [Form Finding]
Form Finding 2 This shape is bound up by 2 different forces with 2 different directions - up and down. There are several anchor points on the ground and we can change the quantity of them. The height of this pavilion is decided by the relationship between these 2 different forces.If the force on the top is stronger than the other one, the hole on the top of this pavilion would be bigger.
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Top
Perspective
Top
Perspective
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CLAY EXTRUDING PAVILION [Subdivision]
Different Subdivision After form-finding, the 3D surface need to be subdivided. Lunch box is used to divid the surface into different kinds of geometry, like diamond, triangle and rectangle. Those kinds of subdivision provide many possibilitis for the next step that components can be designed according to the various geometric subdivisions.
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CLAY EXTRUDING PAVILION [Structure]
Reference
The initial research about the structure of the shingle was based on wooden or steel structure. More specifically, it should be light and stable on which we can attach our tiles.
http://www.spiro.arch.ethz.ch/de/research/reciprocal-frame/ exhibition.html
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http://triangularlatticeroof.blogspot.co.uk/2015/12/joints-wood. html
In order to attatch the tiles onto the structure, the connection has to be well designed based on the shap of the component, the figures below are two examples.
http://www.designboom.com/architecture/enric-ruiz-geli-villanurbs-empuriabrava/
http://www.archdaily.com/469088/king-fahad-national-librarygerber-architekten
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CLAY EXTRUDING PAVILION [Structure]
Option1 Option 1 is to build the structure by steel. The advantages of steel structure are adaptability, costeffectivity, ductility, durability The whole structure is subdivided based on our shingles size and shape. Each rhombus will be screwed with each other so as to build the whole structure. The picture 1&2 shows how the shingle be attached onto the structure.
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At this part, we are planning to use some material that is easily to be drilled, so that the joint bewteen the steel structure and our component can be like a stick.
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Option2 Option 2 is to build the structure by wood. The advantages of wooden structure are flexible design, quick build, and lightweight. In this option, we use a hexagonal steel joint to connect the wooden stick. This kind of frame is more flexible because we can easily change the angle between diffent wooden stick. There is no need to cut accurately, we can adjust the angle be rotating the stick, which makes it easily to shape our frame.
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At this part, we are planning to a steel joint to connect the wooden frame, and inside the joint, a steel stick can be insert to connect the shingles and the frame. The picture 3&4 above shows how the shingle be attached onto the structure.
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CLAY EXTRUDING PAVILION [Structure]
Option3 Option 3 is to build the structure by wooden mortise and tenon. The mortise and tenon joint has been used for thousands of years by woodworkers around the world to join pieces of wood, mainly when the adjoining pieces connect at an angle of 90° . In its basic form it is both simple and strong. Although there are many joint variations, the basic mortise and tenon comprises two components: the mortise hole and the tenon tongue. In this method, there is no need to fabricate another joint like a steel joint, however it also involve bending the wood.
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In this part, a stick can be insert into the hole that we will drill at the crossing of the wood frame, which can be used to attach our shingles onto frame.
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Option4 Option 4 is to build the structure by wood. The advantages of wooden structure are flexible design, quick build, and lightweight. This structure can be build as a contious wooden frame by using double wooden layer that is more stable than a single one. However, this kind of method has to bend wood which calls for an accurate way of fabricate the frame.
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04 In this part, a steel conection can be used to stablize the wooden frame, as well as a point to hang the shingles. The steel lines can be another part to support the shingle. At the cross of the steel line, a secondary connection that to attach the shingles.
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CLAY EXTRUDING PAVILION [Component]
Relationship Between Components There are three methods to connect components in traditional way. The first method is put them as tiles, in another words, they are arranged next to each other. The second way is malposed, but the shape will be destroyed after shrinking as badly as the first one. As for the third one, components is lapped over each other. Even though shrinkage, the shell structure still exists entirely.
Tiled
Before Shrinking
After Shrinking
When Raining
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Malposed
Overlapped
Surface of Component —— 2D or 3D?
2D Robotic Printing As the previous robotic printing, the toolpath only can be printed in one direction, because the nozzle cannot rotate.So it is a limited condition for us to print more free toolpath.
3D Robotic Printing Now we deal with the problem to rotate the nozzle by change the grasshopper script, so toolpath on 3D surface can be printed easily and precisely.
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CLAY EXTRUDING PAVILION [Component]
Component A and Arrangement According to the square subdivision, we draw some circle auxiliary lines to find the shape of component. Finally, the component is classified into two kinds, and they fit together. Every row of components is overlapped to the next row.
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CLAY EXTRUDING PAVILION [Component]
Component A and Variation From the bottom to the top, the component B will be changed from veined surface to soomth surface. The smooth one is the original one, and the veined one is developed from it. As the referrence, the texture on the veined component is more obvious and detailed.
Smooth
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Smooth
Bumped
Bumped
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CLAY EXTRUDING PAVILION [Texture Research]
Option1
Option 1
Option 1
Option 2
Option 1
(Combination)
Option 2
(Combination)
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Option 2
Reference: http://www.spiro.arch.ethz.ch/de/research/reciprocal-frame/exhibition.html
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CLAY EXTRUDING PAVILION [Texture Research]
Option2 This option is based on the inspiration from coral and the breath organ of marine organisms. However, we have not decided whether it is a pattern printed on the surface of one component or a part of one component. We would like to embody the process of growing of coral, and the movement of coral in the sea. The people can feel wind when they stand or sit in the pavilion, it is a great experience of them to feel air and light in this space...
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CLAY EXTRUDING PAVILION [Component]
Shape of Component B Diamond subdivision
Connection of Components
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Diamond Deformation
Control Point Adjustment
Scaling
Plane Move
2D to 3D Surface
Surface Smoothing
Surface Adjustment
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CLAY EXTRUDING PAVILION [Component]
Component B and Subdivision Component A is designed according to the diamond subdivision and arranged overlappedly. So after variation, the component can be built up logically. Changing the control points, the 2D surface component transfer to 3D surface. To adapt to the free form, the shape of every component is unique and changed according the curvature of the form.
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CLAY EXTRUDING PAVILION [Component]
Mould of Component B -1
Print Different Size of Components on the Same Mould
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CLAY EXTRUDING PAVILION [Component]
Mould of Component B —2
Print Different Size of Components on the Same Mould
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CLAY EXTRUDING PAVILION [Component]
Mould of Component B —3
Print on Mould
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Assemble them based on subdivision
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CLAY EXTRUDING PAVILION [Component]
From Component to Whole Shape
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CAMDEN MARKET > Site Introduction > Form Design
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CAMDEN MARKET [Site Introduction]
Site Information This site is located in the center of the camden market, near the north entrance of the market, which is on the chalk farm road. There are thousands of people came here, shopping and eatting and relaxing. This site was used to be an entrance of the undergroud market. The stage used as chatting and relaxing area and there is a small platform which uesd to be a small stage is our site. Our project aim at attrating people into this market and a special spot of the camden town.
few tourists
SITE
lots of tourists
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CAMDEN MARKET [Form Design]
Reference This project called Spineway, designed by Marc Fomes, the project was constructed inside Woodlawn Lake Park in San Antonio, southern Texas. The century-old park is a popular destination for local residents. This project called Pleated Inflation, designed by Marc Fomes, an outdoor installation for a French school, consisting of perforated aluminium plates that cast patterned shadows on the ground.The permanent structure serves as an informal amphitheatre at the LycĂŠe Christian Bourquin, a newly constructed high school in Argeles, France.
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This project is called Armadillo Vault, which is a pioneering structrue that supports itself without any glue. The project is leaded by ETH zurich research team. They constructed an expansive canopy using 399 slabs of limestone and no glue.
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CAMDEN MARKET [Form Design]
Design Prototype There are several different design of the pavillion due to the different control lines of the round site. After computer program there come different shape. Each form has its advantaged and disadvantages. Due to the utility of the pavillion.
Prototype 1
Prototype 2
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CAMDEN MARKET [Form Design]
Design Prototype There are several different design of the pavillion due to the different control lines of the round site. After computer program there come different shape. Each form has its advantaged and disadvantages. Due to the utility of the pavillion.
Prototype 3
Prototype 4
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CAMDEN MARKET [Form Design]
Design Prototype Actually, all of them the form and structure are acceptable, but in order to attract more tourists come into the site, we find several of the pavillion is better than the others, like prototype 1, 2, 5.
Prototype 5
Prototype 6
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CAMDEN MARKET [Form Design]
Design Analysis
SIGHT LINE
SIGHT LINE
PASS-THROUGH
SIGHT LINE
SIGHT LINE
SIGHT LINE
SIGHT LINE FLOW OF CROWD FLOW OF CROWD
When we carefully consider all the factors of a pavillion in the site, like the sight line of both people inside and outside, and the walking path. We find the basic structure of the pavillion site branch, which is one part of the computer program.
FIND THE BASIC LINES
EXTENSION
BASIC MESH
When we generated the basic control lines of the site. It could be developed into the basic mesh of the pavillion. Then we can generate the form of the pavillion.
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This is a picture showing the project on its site. This form matches the site perfectlly and there are several open parts to connect the interial part with the outside world. And it will never block the sight from groud to the undergroud. And it is possible to be fabricate due to its reasonable structure.
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CAMDEN MARKET [Form Design]
Mode Analysis We 3D printed out the pavillion and made the site modle throw CNC and to show clearlly about the size and the space about the site when the pavillion is built there. It looks attracting and add some different thing in the market. We hope it would be the attraction of the whole market.
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We did some research about the pavillion intallation, these 3-4 meter pavillion could be divided into several parts in order to assemble easily. When we install the pavillion we could assemble these parts first and connect them with each other.
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CAMDEN MARKET [Form Design]
Reference These pictures show the normal way of falsework works before the pavillion was built. The scaffold will be insalled before assembling the bricks. And afer the bricks are will assembled the falsework will be removed. Then the pavillion will surport it self with out any glue.
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Structure Analysis Each component is not the same, also the curvature radius is not different, which means it might need the mould to help make the bottom curve surface. We refered to the real project of shell pavillion, and made two different kind of scaffold, one is metal strcture, another is timber structure. Both of them are light struture and easy to build and remove.
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CAMDEN MARKET [Form Design] Proposal
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