MANIFOLD ASSEMBLIES Digital Ceramic with Wood Structure for RIBA
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 CATMULL-CLARK SURFACE CONCEPT > component > printing > aggregation
02 PROJECT BACKGROUND > CONCEPT background > site introduction
03 WOOD STRUCTURE > sturcture design > growth distribution > structure installation
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04 BATWING MINIMAL SURFACE > MINIMAL SURFACE COMPONENT > COMPONENT ASSEMBLING > COMBINATION OF COMPONENT AND STRUCTURE
05 FABRICATION > robotic printing > mold > slip casting > firing >installation
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CATMULL-CLARK SURFACE CONCEPT > Component > Printing > Aggregation
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CATMULL-CLARK SURFACE CONCEPT [COMPONENT]
Difference between Rectangle and Catmull Clark Surfacce
rectangular surface
Catmull–Clark surface
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sharp shange angel
smooth shange angel
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CATMULL-CLARK SURFACE CONCEPT [COMPONENT]
Component Variety cube geometry
curvey block
cube geometry
curvey block
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CATMULL-CLARK SURFACE CONCEPT [COMPONENT]
Component Transformation
cube geometry
curvey block
cube geometry
curvey block
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CATMULL-CLARK SURFACE CONCEPT [COMPONENT]
Dimension of Component
x=1, y=1, z=1
x=1, y=1, z=0.5
length: 300mm wideth: 300mm thickness: 300mm
length: 300mm wideth: 300mm thickness: 150mm
Max degree=70
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Max degree=64
x=1, y=2, z=0.5 length: 300mm wideth: 600mm thickness: 150mm
Max degree=64
x=1, y=2, z=1 degree=66
x=2, y=2, z=1
length: 300mm wideth: 600mm thickness: 300mm
length: 600mm wideth: 600mm thickness: 300mm
Max degree=66
Max degree=56
x=2, y=2, z=2 length: 600mm wideth: 600mm thickness: 600mm
Max degree=70
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CATMULL-CLARK SURFACE CONCEPT [PRINTING]
Printing Method
flat mold
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mold with addition
nal holder
flat mold with white additional mold
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CATMULL-CLARK SURFACE CONCEPT [PRINTING]
Printing Mold and Test
Layer two
Gap
Mold 2
Layer one Main mold
Layer two
Gap
Layer one
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Main mold
01
01 Short Component length: 300mm wideth: 300mm thickness: 180mm 02 Long Component length: 300mm wideth: 600mm thickness: 180mm
long component length: 300mm wideth: 600mm thickness: 180mm
02
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CATMULL-CLARK SURFACE CONCEPT [PRINTING]
Printing Mold and Test
FIRST TEST
SPEED OF ROBOT
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MAXIMUN ANGLE OF ROBOT
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FIRST LAYER HIGHT
4MM
DISTANCE BETWEEN LINES
5MM
MAXIMUM ANGLE OF MOULD
20
70
SECOND TEST
Perspective SPEED OF ROBOT
10
MAXIMUN ANGLE OF ROBOT
30
FIRST LAYER HIGHT
8MM
DISTANCE BETWEEN LINES
5MM
MAXIMUM ANGLE OF MOULD
70
Top view
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CATMULL-CLARK SURFACE CONCEPT [PRINTING]
Printing Mold and Test
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Perspective
Perspective
Top view
Perspective
THIRD TEST
SPEED OF ROBOT
15
MAXIMUN ANGLE OF ROBOT
30
FIRST LAYER HIGHT
9MM
DISTANCE BETWEEN LINES
5MM
MAXIMUM ANGLE OF MOULD
70
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CATMULL-CLARK SURFACE CONCEPT [AGGREGATION]
Aggregation Logic
brick system
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bounding box
rendering
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CATMULL-CLARK SURFACE CONCEPT [AGGREGATION] Aggregation
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CATMULL-CLARK SURFACE CONCEPT [AGGREGATION]
Aggregation Screen
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PROJECT BACKGROUND > Concept > Site
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PROJECT BACKGROUND [CONCEPT]
To celebrate UKGBC’s
10th Anniversary
Brief:
- A sculpture representing the values of the UK Green Building Council (UKGBC) to celebrate their
10th Anniversary.
- To be erected as part of a workshop with 12 members of staff from the UKGB at the Royal Institute of British Architects on Thursday 28th September - To be unveiled that evening at the 10th Anniversary event (ie. a one-day install) - To potentially be relocated (in parts or as a whole) to the offices of various members of the UKGBC
Budget:
£1000 research & development (samples, models, mock-ups)
£6000 final fabrication (materials, labour, transport, install, de-install)
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timber, steel and clay. The fact that the timber is repurposed from Design Museum’s project, that the steel has been manipulated as little as possible to allow it to be re-used, Materially, the piece uses a simple palette of three materials:
and that the ceramic elements have been fabricated locally from British clay, are all secondary to the larger concept. Finding ways to limit material waste, financial excess, and resource consumption should be, as the UKGBC has phrased it, ‘second nature’ by now. Rather, what the piece seeks to champion is the ‘coming together’ – of materials, people, processes and ideas.
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PROJECT BACKGROUND [CONCEPT]
What is the Ceramic and Pavilion?
Used materials
Upcycling of
[ Re-manu
Used wood
Used clay
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Sanding
Slip ma
f materiality
Recreation in different function
ufacture ]
g down
Facade
aking
Facade
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PROJECT BACKGROUND [CONCEPT]
Do we recognise how much materials we waste?
x3
The effects of construction activity on waste production are enormous. The industry produces 109m tonnes of construction waste each year (24% of total waste), of which up to 13% is delivered and unused. It produces three times more waste than all UK households combined. Although around half of this waste is reused or recycled, the amount that is simply disposed of remains alarming. ‘Construction and Sustainable Development’ Plain English, Constructing Excellence, Section 6, Page 1, 01/01/08
Than Total Waste of All UK households
109m Tonnes
Construction Waste
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24%
Total Waste
what material we gonna do recycling? 200mm
300mm
(1.75 times exceeded for need) Wasted Clay Total Amount << Recycling
6400mm
3800mm Need Production Output
Tile Production Total Output Sep
Nov
Dec
Feb
[Clay Resources]
Jan
Feb
Mar
April
T:40mm
T:30mm
(x10)
(x22) [Wood Resources]
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PROJECT BACKGROUND [SITE]
RIBA Introduction
BUILDING: ROYAL INSTITUTE OF BRITISH ARCHITECTS
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PLAN : 1ST FLOOR OF RIBA
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PROJECT BACKGROUND [SITE]
Site Analysis
section AAâ&#x20AC;&#x2122;
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B
A
A’
B’
section BB’
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WOOD STRUCTURE > Structure Design > Growth Distribution > Structure Installation
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WOOD STRUCTURE [STRUCTURE DESIGN]
Structure Design Step1
Wood Unit
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WOOD STRUCTURE [STRUCTURE DESIGN]
Structure Design Step2
Create a Surface to Control Wood Units
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A Half-enclosed Shape to Cater for Visiting
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WOOD STRUCTURE [STRUCTURE DESIGN]
Structure Design Step3
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WOOD STRUCTURE [STRUCTURE DESIGN]
Structure Design Step4
Create a Wave Surface to Control Rising and Fall of the Top Area
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A Wave Curve Would Make the Structure a Sense of Floating
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WOOD STRUCTURE [STRUCTURE DESIGN]
Structure Design Step5
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Some trees can be introduced in this system and make an artistic conception of a relationship between people and architecture and nature.
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WOOD STRUCTURE [STRUCTURE DESIGN]
Structure Design Step6
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For some parts, we adjust the density of wood structure (crossed part). Furthermore, we add some wood bars to make the whole structure tensile.
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WOOD STRUCTURE [GROWTH DISTRIBUTION] Structure Layers
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LAYER 1
LAYER 2
LAYER 5
LAYER 6
LAYER 3
LAYER 7
LAYER 4
LAYER 8
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WOOD STRUCTURE [GROWTH DISTRIBUTION] Component Installation
STAGE 1
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STAGE 2
STAGE 3
STAGE 4
STAGE 5
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WOOD STRUCTURE [STRUCTURE INSTALLATION] Structure Types
TYPE 2
TYPE 1
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TYPE 5
TYPE 4
TYPE 3
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WOOD STRUCTURE [STRUCTURE INSTALLATION] Structure Types
type 1 details
type 1 aggregation
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type 1
type 2 details
type 2 aggregation
type 2
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WOOD STRUCTURE [STRUCTURE INSTALLATION] Structure Types
type 3 details
type 3 aggregation
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type 3
type 3 details
type 3 aggregation
type 3
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WOOD STRUCTURE [STRUCTURE INSTALLATION] Structure Types
STEP 1
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STEP 2
STEP
P3
STEP 4
STEP 5
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WOOD STRUCTURE [STRUCTURE INSTALLATION] Final Structure
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BATWING MINIMAL SURFACE > Minimal Surface Component > Component Assembling > Combination of Component and Structure
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BATWING MINIMAL SURFACE [MINIMAL SURFACE COMPONENT] Generating Process
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step1
ste step
step4
step
step7
ste step
ep2 p2
step3
p5
step6
ep8 p8
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BATWING MINIMAL SURFACE
step1
[MINIMAL SURFACE COMPONENT]
type 4
Component Study Minimal Surface
type 3
type 2
type 1
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step2
step3
step4 overall geometry
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BATWING MINIMAL SURFACE [MINIMAL SURFACE COMPONENT] Surface Stiffness
synclastic surface
anticlastic surface
1
2
3
4
5
6
7
8
9
10
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generating process
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elevation
first layer analysis
perspective
second layer analysis
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BATWING MINIMAL SURFACE [MINIMAL SURFACE COMPONENT] Minimal Surface Save Material
bounding box
curvey geometry
short component: 0.212 m2 volume: 0.18 m3 area/volume ratio: 1.17 length: 300mm wideth: 300mm thickness: 150mm
long component: 0.34 m2 volume: 0.22 m3 area/volume ratio: 1.54 length: 300mm wideth: 600mm thickness: 100mm
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0.18m3
0.22m3
0.08m3
minimal surface: 0.09 m2 volume: 0.08 m3 area/volume ratio: 1.125 length: 300mm wideth: 300mm thickness: 150mm
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BATWING MINIMAL SURFACE [COMPONENT ASSEMBLING] Development of Mold
part 2
part 3
front view
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back view
part 1
mold 2
mold 3
plan
elevation
perspective
mold 1
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BATWING MINIMAL SURFACE [COMPONENT ASSEMBLING] Component and Structure
old mold only can print one type of component
new mold for printing
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component
section AA
component
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BATWING MINIMAL SURFACE [COMPONENT ASSEMBLING] Toolpath Development
type1
type4
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type2
type3
type5
type6
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BATWING MINIMAL SURFACE [COMPONENT ASSEMBLING] Universal Mold
empty
mold
m
mold
option
3
mold
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option
4
mold op
tion 1
mold
mold op
option
2
tion 5
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BATWING MINIMAL SURFACE [COMPONENT ASSEMBLING]
Different Types of Minimal Surface
type 1
type 1.1
type 2
type 2.1
type 3
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type 4
type 4.1
type 4.2
type 5
type 5.1
type 5.2
type 5.3
type 5.4
type 5.5
type 6
type 6.1
type 6.2
type 6.3
type 6.4
type 6.5
type 7
type 7.1
type 7.2
type 7.3
type 7.4
type 7.5
type 8
type 8.1
type 8.2
type1
type2
type3
type4
type5
type6
type7
type8
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE] Gradually Varied Facade
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE] Varied Unit
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE] Varied Unit
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE] Facade
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE] 3 Design Options
option1 4 components in 1 Box FRAME Hang on structure
option2 1 components in 1 Box FRAME Cupboard structure
option3 4 components in 1 Box FRAME Fitting structure
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option 1 elevation
option 2 elevation
option 3 elevation
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE]
Option1 4 components in 1 Box FRAME
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1000mm
500mm
420mm elevation
option 1
perpective
option 1 elevation
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE]
Option1 Hang on Structure
1 timber unit
axonometric with component
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axonometric with component
section AA
section BB
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE]
Option2 1 components in 1 Box FRAME
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1100mm
980mm
480mm elevation
option 2
perpective
option 2
perspective
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE]
Option2 Cupboard Structure
assemble 1 unit
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1 unit
axonometric with component
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE]
Option3 4 components in 1 Box FRAME
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1000mm
500mm
420mm
elevation
option 3
perpective
option 3
perpective
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE]
Option3 Fitting Structure
Fitting structure
Component assembling
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1 unit
axonometric with component
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BATWING MINIMAL SURFACE
[COMBINATION OF COMPONENT AND STRUCTURE]
Connection between Wood and Ceramic Pieces
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axonometric with component NUT METAL RING WOOD BAR METAL RING RUBBER RING CERAMIC PIECE RUBBER RING BOLT
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FABRICATION > Robotic Printing > Mold > Slip Casting > Firing > Installation
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FABRICATION [Robotic Printing]
Form Finding by Robot Printing After the printing, we are waiting for 1 day, the will be nice surface. It will not crack. In order to take out of the component, we cut the one opening to make it easily. In order to take out the clay component easily, we change the mold to plaster. Because plaster can absorbe the water in clay. But we have to take the clay within 1 day, otherwise the clay will crack.
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top view of crack
top view of crack
top view of crack
top view of crack
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FABRICATION [Mold]
CNC Mold and Plaster Mold
01
02
03
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01 Making plaster by CNC mold to support printing. 02 Making negative mold by plaster. 03 Plaster mold
01
02
01 &02 Fixing the plaster mold 03 Key of Plaster Mold
03
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FABRICATION [Slip Casting]
01
01& 02 Positive plaster mold and negative plaster mold.
02
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03 Slip Casting
03
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FABRICATION [Slip Casting]
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FABRICATION [Slip Casting]
01
02
03
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01 & 02 & 03 Slotting 04 &05 Joint half pieces by slip
04
05
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FABRICATION
[Firing and Installation] Biscuit Firing
Glaze Firing
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Installation
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FABRICATION
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