BPro RC6 2015/16_CONEcrete

C NEcrete

Team Members: Haibo Xiao | Liyuan Ma | Qiaochu Wang | Sanchutha Choomsai Tutors: Daniel Widrig | Soomeen Hahm | Igor Pantic | Stefan Bassing Research Cluster 6, MArch Architectural Design, 2015 - 2016 The Bartlett School of Architecture | UCL 2016.07

INTRODUCTION Inspired by some metal aggregation studies, we started our research and design from the simplest geometry---cone, which has the advanteges to rotate at any directions and can break or grow at any branches.

For the material reseach, with the aim of finding strong but lightweight haderning method, we use the most common construction material----concrete by mixing it with other plaster materials.

Basically, we aggregate our components by making cones into curves first, then combine them according to the digital form-finding outcomes. After that, we applied concrete on it to harden it.

CONTENTS Chapter 1: Initial Approach -Initial Concepts -Initial References -Initial Attempts Chapter 2 : Fabrication Research -Component Study -Material Comparison -Strenghth Test Chapter 3 : Digital Setup -Bundle System -Branching System -Prototype Tests Chapter 4 : Design Development -Branching Bundles Chapter 5 : Prototype Fabrication -Prototype -Chair Fabrication -Stool Fabrication Chapter 6 : Architectural Potential -Surface Study -Column Study -Staircase Study -Space Design

CHAPTER

01

INITIAL APPROACH At the very first beginning, we were inspried by some aggregating art works by various artists or architects, such as Neri Oxman, Iris Van Herpen, Tobias Stenico, Jose Sanchez & Alisa Andrasek.

We were rather interested in the aggregation of simple compnents by arraying and stacking, in order to create some interesting patterns like spiral growth.

Starting from the references, we tried to make some small physical sculpture by simply cutting and folding metal sheets. With these easily-made cone shape components, we used stacking and arraying to connect cones.

[ Component Aggregation ] Inspired by the patterns in the artworks of Neri Oxman, Iris Van Herpen and so on, we were interested in the aggregation of simple compnents by arraying and stacking, in order to create some interesting patterns like spiral growth.

Form Reference Image 1: Rapid Craft, Neri Oxman, 2005-2006

Form Reference Image 2: Metal Dress, Iris Van Herpen

Form Reference Image 3: Bloom-the Game, Jose Sanchez & Alisa Andrasek

Initial Approach | References [ Material Reference ] For the hardening material, we tried to use the most common construction material----concrete, for its strehgth, stability and interesting patterns when combined with mesh.

Material Reference Image 1: Untitled Project, Nick van Woert, 2011 Material: Kitty Litter, plaster statue, stainless steel, urethane Size: 180 x 50 x 50 cm

Material Reference Image 2: Untitled Project, Nick van Woert,2014 Material: Coal slag, steel and white bronze

Material Reference Image 3: Christinabali, nadiahshahril, Chrysanthitzovla,2014 Material: jesmonite plaster, paster polymer, trisodium citrate , water

[ Initial Attempts ] Starting from the references, we tried to make some small physical sculpture by simply cutting and folding metal sheets. With these easily-made cone shape components, we used stacking and arraying to connect cones.

[ Tools ]

Side Array

1

Stacking

Interlocking

Image 1: Metal sheet Image 2: Scissor to cut the sheet material Image 3: Pen to roll the sheet into cones Image 4: Plier to strengthen the cone shape

Simple cones

Aggregation

Initial Initial Approach Approach | References | Attempts

First Aggregation Sculpture

[ Initial Attempts ] This initial attempt was completely made by simple tools and hands. By arraying, stacking and interlocking the cones in a spiral pattern, the outcome turnt out to be interesting and has various potentail for aggregation.

Coal Image 1: Coal Image 2: Concrete Image 3: Glue

Concrete

Glue

Initial Approach | References

CHAPTER

02

FABRICATION RESEARCH In this chapter, we focus on the material tests and fabrication method. Starting from comparing different materials property to make a simple cone shape, we found the aluminium mesh is very lightweight, strong, flexible and its surface make it easy to attach to hardening material. Then we researched how to fabricate it manually and machanically. After that, we compared with different kinds of concrete to harden it.

[ Geometry Study ] We study three basic geometry shapes which are triangular base pyramid, rectangular base pyramid, and a simple cone. Both of the pyramid shapes allows more surface of connection, make it more easier to join side by side with another components. However the cone shape make it possible for 360 degree branching as well as create a spiral pattern when stacking linearly while the pyramid shapes with surface cannot.

Basic Shape

Geometries

Triangle

Triangular Base Pyramid

Square

Regtangular Base Pyramid

Circle

Simple Cone

Side Array with Alignment

Side Array with Shift

Linear Stac

cking

Fabrication Research | Geometry Study

Linear Stacking with Shift

Spiral Linear Stacking

Branching

Evaluation

• Surface make it

easy for side array

• Easy for Linear

Stacking

• Cannot create

spiral linear stacking

• With triangular base

shape results in branching to limited direction

• Surface make it

easy for side array

• Easy for Linear

Stacking

• Cannot create

spiral linear stacking

•With rectangular base

shape results in branching to limited direction

•Less surface make it difficult for side array • Easy for Linear Stacking • With circular base shape make it possible for spiral linear stacking • With circular base shape result in braching to 360 degree direction

[ Material Properties ] By comparing a wide range of materials, such as papaer, plastic sheet, felt sheet, aluminium sheet, prepreg carbon fiber and aluminium mesh, by its properties, deformability and price. We found the aluminium mesh is the best material for its flexibility, stability and ability to attach concrete.

Materials

Thickness

Shaping to a single Cone

Deformability

Cones Aggregation

Paper

Plastic Sheet

Felt Sheet

0.3 mm

0.5 mm

1.0 mm

Fabrication Research | Material Study

Aluminium Sheet

Prepreg Carbon Fibre

Aluminium Perforated Sheet

0.1 mm

0.75 mm

0.5 mm

[ Conclusion ] The aluminium mesh is the best material for its flexibility, stability,deformability and ability to attach hardening material

[ Material Property ] 1) Easy to cut into equal size 2) Easy to roll into cone shape 3) Strong and always stay in shape 4) Easy to attach concrete

Easy to cut

Easy to connect

Fabrication Research | Aluminium Mesh

[ Mass Manufacturing Potential] A single chair may need hundreds of cone components. So it is an urgent task for us to find a faster, cheaper and more convenient way to producecones. We tried to use water jet cutting machine for its preciseness.

Water Jet Cutting

Laser Cutting

[ Cone-making Options ] Making a cone is easy, just need some simple tools, like scissors and hands, to cut it along its mesh, and roll it around some moulds, like pencil or cone-shape objects.

If more preciseness is required, we can use the water jet machine to cut it.

Option 1: Manual modeling

Step 1: Cut the mesh

Step 2: Basic shape

Step 1: Take out the mesh

Step 2: Basic shape

Option 2: Machine-assisted modeling

Fabrication Research | Aluminium Mesh

Step 3: Roll the mesh

Step 4: Stack into the holes

Step 5: Cone made!

Step 3: Use the mould

Step 4: Roll the mesh

Step 5: Cone made!

[ Standardized Segment ] Design Process: 1.Make standardized cones.(Cone Diametre:3cm, Cone Length: 9cm) 2.Make standardized cone segment.(By connecting at the 11th point and rotate 20 degree, the segments will have four possible growing positions) 3.Design guide curves 4.Apply the 4-cone segments onto the guide curves(By randomly choosing one of the four possible growing positions) 5.Branch out to form surfaces

3.00

9.00

9:

20.00

: 11 Standardised Cone

Rotate 20 Degrees

Standardised

d Segment

Fabrication Research | Component Size

Four Future Growth Positions

[ Component System ] Based on our design language study, we tried to set some rule to aggregate the component together.

First is using 4 cones as one component, then we can aggregate with another component by stacking and branching.

1.Single components

2. Stacking

3. Branching

Fabrication Research | Physical Model-making

5.Reinforced sculpture

[ Coating Strategy ] We study diferent materials to apply on the surface of the aluminium mesh component in order to test which material is the most suitable to make each component connect together.

As a result Polyurethane rubber is the most stable because it can bond and connect the Aluminium mesh very well.

Expanding Foam

1st Coat

2nd Coat

Adhesive Spray

Plastic Spray

Materials : Expanding Foam

Materials : Adhesive Spray

Materials : Plastic Spray

Curing Time : 1 hours

Curing Time : 2 hours

Curing Time : 1 hours

Weight : 18 g

Weight : 16 g

Weight : 17 g

Fabrication Research | Coating Strategy

Epoxy Resin

Rubber Spray

Polyurethane Rubber

Materials : Epoxy Resin

Materials : Rubber Spray

Materials : Polyurethane Rubber

Curing Time : 8 hours

Curing Time : 2 hours

Curing Time : 3 hours

Weight : 18 g

Weight : 15 g

Weight :29 g

[ Strength Test ] We put each brach of diferent material on a frame, use a weigher to pull the branch down, and record the force when the branch is broken.

As a result, Polyurethane rubber are the most strongest material.

Expanding Foam

Adhesive Spray

Plastic Spray

6 kg

8 kg

5 kg

Load Bearing Unit kg

10

5

0

Fabrication Research | Coating Strategy

Epoxy Resin

Rubber Spray

Polyurethane Rubber

4 kg

5 kg

9 kg

[ Reinforcement Strategy ] We study diferent materials to apply on the surface of the aluminium mesh component in order to test which material is the most suitable to make the component stronger and more stable.

As a result, Concrete, and Concrete mix with PVA powder are the most stable and the lightest material.

Plaster

White Cement

PVA Powder

Materials : Plaster 80% , Water 20%

Materials : Cement 80% , Water 20%

Materials : PVA Powder 80% , Water 20%

Curing Time : 2 hours

Curing Time : 3 hours

Curing Time : 1 hours

Strength : Not Strong

Strength : Strong

Strength : Strong

Weight : 32g

Weight : 48g

Weight : 40g

Deformability : Breakable

Deformability : Non deformable

Deformability : Non deformable

Finishing : White , be able to see the mesh pattern

Finishing : White , be able to see the mesh pattern

Finishing : White , barely see the mesh pattern

h

Fabrication Research | Coating Strategy

PVA Powder50% : Concrete 50%

Materials : PVA Powder 40% , Concrete 40%, Water 20% Curing Time : 5 hours Strength : Strong Weight : 57g Deformability : Non deformable Finishing : Grey , mesh pattern hardly appearing

Concrete

Materials : Concrete 80% , Water 20% Curing Time : 24 hours Strength : Strong Weight : 73g Deformability : Non deformable Finishing : Dark Grey , mesh pattern hardly appearing

Fibre Concrete

Materials : Polypropylene Fibre 10%, Concrete 70% , Water 20% Curing Time : 24 hours Strength : Strong Weight :53g Deformability : Non deformable Finishing : Dark Grey , Difficult to apply ont he surface, mesh pattern hardly appearing

[ Strength Test ] We put each brach of diferent material on a frame, use a weigher to pull the branch down, and record the force when the branch is broken.

As a result, Concrete, and Concrete mix with PVA powder are the most strongest material.

Plaster

White Cement

PVA Powder

2 kg

2 kg

7 kg

Load Bearing Unit kg

10

5

0

Fabrication Research | Coating Strategy

PVA Powder50% : Concrete 50%

Concrete

Fibre Concrete

9 kg

9 kg

7 kg

[ Material Comparison ] From the material teest, we found two possibility material to be apply on the mesh which are Concrete and PU Rubber.

Rubber when cover on the mesh, is able to connect the components together as well as giving the flexibilty for the aggregation.

Concrete can connect each component but not the flexibility, however it is very stong and stable.

Materials :PU Rubber 1 Coat Strength : Not Strong Finishing : Mesh pattern still appearing

Rubber

Materials : Concrete 1 Coat Strength : Quite Strong Finishing : Mesh pattern still appearing

Concrete

Fabrication Research | Coating Strategy

Rubber

Concrete

[ PVA Poweder ] As we selcted PVA powder as our final coat, we experimented with spraying on our component from 1 to 3 times, and did the strength test.

Step 1: PVA Powder

Step 2: Mix with water

Step 3: Spray

Load B Unit

1

5

0

Fabrication Research | Coating Strategy

1st Coat

2nd Coat

3rd Coat

Bearing t kg

10

5

0 7 kg

8 kg

9 kg

[ Concrete ] We test how many layer of concrete needed to cover the alumunium mesh in order to make the prototype as strong as possilble.

Materials :Aluminium Mesh

Materials :Aluminium

Strength : Not Strong

Strength : Not Strong

Finishing : Mesh pattern hardly appearing

Finishing :Be able to se

Fabrication Research | Coating Strategy

Mesh + Concrete 1 Coat

ee mesh pattern

Materials :Aluminium Mesh + Concrete 5 Coat Strength : Very Strong Finishing : Mesh pattern hardly appearing

CHAPTER

03

DESIGN SETUP In this chapter, we focus on the material tests and fabrication method. Starting from comparing different materials property to make a simple cone shape, we found the aluminium mesh is very lightweight, strong, flexible and its surface make it easy to attach to hardening material. Then we researched how to fabricate it manually and machanically. After that, we compared with different kinds of concrete to harden it.

Main Options | Design Language

CHAPTER

05

PART 1: BUNDLE SYSTEM

[ Design Language ] Based on the our studies, we can make a library of design languages of simple bundle, bottom opening, middile opening, top opening, twisting, bending, branching.

With these basic design languages, we can aggregate them into complex forms.

Simple Bundle

0 Degree Rotation

45 Degree Rotation

90 Degree Rotation

Bottom O

Opening

Design Setup | Bundle Syetem

Middle Opening

Top Opening

Bending

[ Physical Prototypes ] We explore a varaity of design language through the aggregation of physical prototypes such as spiral pattern, and twisting pattern.

Aluminium Mesh

Concrete Reinforcement

Aluminium Mesh

Design Setup | Bundle Syetem

Concrete Reinforcement

Spiral Prototype

[ Digital Sketches ] Based on the design language study, we tried to make larger pieces by combining different deformation.

Design Setup | Bundle Syetem

Digital Sketch

[ Digital Sketches ] - The diagram illustrate through positive electrode and negative pole to expain different direction of cone.

- A variety of pattern can be created through these graphics system.

Pattern Connection

-

+ A

+ + + - + - + + + -

Second rotation area First rotation area

B

C

Simple Bundle

Design Setup | Bundle Syetem

Different areas Rotation

Combination

+

- + - - + + + + + - + - - + -

- + + + - + - + + + -

+

+

+ - - + + + - -

Rotation

- + - - + + + + + - + - - + -

- + + + - + - + + + -

[ Design Process ] Through scaling,branching and combing,the column design become much more complex.

-

+

Design Setup | Bundle Syetem

[ Design Process ] Through scaling,branching and combing,the column design become much more complex.

Side View

Step 1.Prototype

Back View

Step 2.Bend line

Step 3.Bend angle

Step 4.Forming famework of Chair

Design Setup | Bundle Syetem

Opt1.Front View

Opt2.Front View

[ Design Process ] Through scaling,branching and combing,the column design become much more complex.

Step 1.The formation of the support stucture

Step 2.The formation of the column

Step 4.Simplified the line

Step 5.Forming construction of staircase

Step 3.Simplified the line

Design Setup | Bundle Syetem

Perspective View

[ Digital Sketch ] By combining the design languages we have, we design some spaces like this.

Top view

Support part details

Stairstep Details

Support part details

Design Setup | Bundle Syetem

Perspective View

[ Digital Sketch ] By combining the design languages we have, we design some spaces like this.

Perspective View

Design Setup | Bundle Syetem

Top View

Perspective View

Perspective View

Design Setup | Branching Syetem

CHAPTER

05

PART 2: BRANCHING SYSTEM

[ Generation Process ] An L-system or Lindenmayer system is a parallel rewriting system and a type of formal grammar. An L-system consists of an alphabet of symbols that can be used to make strings, a collection of production rules that expand each symbol into some larger string of symbols, an initial “axiom� string from which to begin construction, and a mechanism for translating the generated strings into geometric structures.

L-systems were introduced and developed in 1968 by Aristid Lindenmayer, a Hungarian theoretical biologist and botanist at the University of Utrecht. Lindenmayer used L-systems to describe the behaviour of plant cells and to model the growth processes of plant development. L-systems have also been used to model the morphology of a variety of organisms[1] and can be used to generate self-similar fractals such as iterated function systems.

Recursion 1 Angle Parameters Curvature: 0;3;12; Branch: -39;69;45; Spiral: 39;39;-35;

Angle Parameters Curvature: 12;0;-6; Branch: 15;15;15; Spiral: 30;30;-30;

Angle Parameters Curvature: 15;0;-15; Branch: 15;15;15; Spiral: 30;30;-30;

Angle Parameters Curvature: 15;15;15; Branch: -30;60;45; Spiral: 30;30;-30;

Recursion 2

Design Setup | Branching Syetem

Recursion 3

Recursion 4

Recursion 5

Recursion 6

[ Generation Process ] - It is generated by L-System and Vector Field in Processing - By adjusting its branches from simple to complex to aggregate.

5 Branches

7 Branches

L-System

Vector Field

Form

Simple Aggregation---------------------------------------------------------------------------------------------------------------------

Design Setup | Branching Syetem

9 Branches

11 Branches

13 Branches

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------Complex Aggregation

[ L-system Optimization ] Using L-system to generate the branching structure,then optimizing line to create curves.By using grasshopper,tansform curves into our cone ,add arm part of chair.

1.Prototype

2.simplified the line

4.Bend angle

5.Optimizing line

3.Bend line

6.Forming famework of Chair

Design Setup | Branching Syetem

Details

Side View

Back View

[ Guided Growth ] We study the different curvatures created through 3 different connection points which are 1/4, 1/2 , and 3/4. With different cone diameter and length can create different curvatures.

Guided Grwoth Procedure

Step 1: Guide curve

Single line

Guided Grwoth Procedure

Step 2: One-directional gr

rowth

Design Setup | Branching Syetem

Guided Grwoth Procedure

Step 3: Multi-direction grwoth

Linear aggregation

[ Guided Growth ] We study the different curvatures created through 3 different connection points which are 1/4, 1/2 , and 3/4. With different cone diameter and length can create different curvatures.

Guided Grwoth Procedure

Step 1: Bounding Box

Guided Grwoth Procedure

Step 2: Guide Curves

Guided Grwoth Proced

Step 3: Symmetric

dure

c Curves

Design Setup | Branching Syetem

Guided Grwoth Procedure

Step 4: Segmented Growth Along the Curve

Guided Grwoth Procedure

Step 5: Segmented Growth Along the Curve

[ Digital Prototype ] We study the different curvatures created through 3 different connection points which are 1/4, 1/2 , and 3/4. With different cone diameter and length can create different curvatures.

Digital Model

Design Setup | Branching Syetem

[ Physical Prototypes ] We explore a varaity of design language through the aggregation of physical prototypes such as branching, and side connection.

Multi-directional Prototype

Multi-directional Prototype

Multi-directional Prototype

[ Sitting Object Design ] Using L-system to generate the branching structure,then optimizing line to create curves.By using grasshopper,tansform curves into our cone ,add arm part of chair.

Step 1: Bounding Box

Step 2: Guide Curves

Step 3: Symmetric Curves

Design Setup | Branching Syetem

Step 4: Segmented Growth Along the Curve

Step 5: Segmented Growth Along the Curve

Step 6: Segmented Growth Along the Curve

[ Sitting Object Design ] Using L-system to generate the branching structure,then optimizing line to create curves.By using grasshopper,tansform curves into our cone ,add arm part of chair.

Perspective View

Design Setup | Branching Syetem

Side View

Back View

Perspective View

[ Sitting Object Design ] Using L-system to generate the branching structure,then optimizing line to create curves.By using grasshopper,tansform curves into our cone ,add arm part of chair.

Sitting Object Design

Sitting Object Design

Sitting Object Design

Sitting Object Design

Iteration 1

Iteration 3

Iteration 2

Iteration 4

Design Setup | Branching Syetem

Sitting Object Design

Iteration 5

[ Digital Sketch ] We study the different curvatures created through 3 different connection points which are 1/4, 1/2 , and 3/4. With different cone diameter and length can create different curvatures.

Guided Grwoth Procedure

Step 1: Two guide curves

Simple Aggregation

Guided Grwoth Procedure

Step 2: Six guide curves

Complex Aggregation

Design Setup | Branching Syetem

Guided Grwoth Procedure

Step 3: Multiple guide curves

[ Recursive growth-system ] -Recursive growth system is based on the method of makingphysical and digtal modeling. It may accelerate the speed of modeling whlie creating some new combinaitons and elements.

-Different growth position will lead to different results.

d c b

a

Type 1

Gen= 2 angle=random.uniform(0,360)

d c b

Type 2

Gen= 2 angle=random.uniform(0,360)

Design Setup | Branching Syetem

Type1+Type2(Gen=2)

Type1+Type2

[ Recursive growth-system ] -Recursive growth system is based on the method of makingphysical and digtal modeling. It may accelerate the speed of modeling whlie creating some new combinaitons and elements.

-Different growth position will lead to different results.

Design Setup | Branching Syetem

[ Recursive growth-system ] -Recursive growth system is based on the method of makingphysical and digtal modeling. It may accelerate the speed of modeling whlie creating some new combinaitons and elements.

d c b

a

Type 1

angle=random.uniform(0,360) Gen= 200

angle=random.uniform(0,1 Gen=200

angle=random.uniform(0,360) Gen= 200

angle=random.uniform(0,1 Gen= 200

d c b

Type 2

Design Setup | Branching Syetem

180)

angle=random.uniform(0,90) Gen=200

180)

angle=random.uniform(0,90) Gen= 200

Type1+Type2

[ Digital Sketch ] -Recursive growth system is based on the method of makingphysical and digtal modeling. It may accelerate the speed of modeling whlie creating some new combinaitons and elements.

Perspective View

Design Setup | Branching Syetem

Details

Side View

Back View

[ Design Process ] -Recursive growth system is based on the method of makingphysical and digtal modeling. It may accelerate the speed of modeling whlie creating some new combinaitons and elements.

Step 1.Forming famework of Chair

Step 4.Following guide growth

Step 2.choose the main frame

Step 5.Combine with other branches

Step 3.Transform the regular cone to connect

Design Setup | Branching Syetem

Top View

Side View

Perspective View Back View

CHAPTER

04

DESIGN DEVELOPMENT For this part, we are trying to do a fundamental component reseach of the reasons why we chose the cone shape, the parameters of cones, the different curvature, the design language library.

[ Digital Sketch ] Based on our design language study, we tried to create a sculptural piece by combining different design language as well as different size of cones.

Design Language

Design Language

Option 1: Bundle System

Option 2: Branching System

+

Linear Aggregation

Branchy Aggregation

Design Development | Branching Bundles

Design Language

Feature 1:

Branching system provides infinite growing possibilities to form larger aggregation.

Design Language

=

Feature 2:

Bundle system provides this whole object the structual meaning and gives it recognisable pattern.

[ Digital Sketch ] Based on our design language study, we tried to create a sculptural piece by combining different design language as well as different size of cones.

Design Language

Feature 1:

Branching system provides infinite growing possibilities to form larger aggregation.

Design Langua

Feature 2:

Bundle system whole object meaning and g nisable pattern

age

m provides this the structual gives it recogn.

Design Development | Branching Bundles

[ Table Design ] Based on our design language study, we tried to create a sculptural piece by combining different design language as well as different size of cones.

Design Language

Design Language

Feature 2:

Feature 1:

Bundle system provides this whole object the structual meaning and gives it recognisable pattern.

Branching system provides infinite growing possibilities to form larger aggregation.

Front View

Design Development | Branching Bundles

Side View

Back View

Perspective View

CHAPTER

05

PROTOTYPE FABRICATION For this part, we are trying to do a fundamental component reseach of the reasons why we chose the cone shape, the parameters of cones, the different curvature, the design language library.

[ Branching Prototype ] After aggregation, we applied concrete mixed with PVA powder on the surface of the model in order to strengthen and harden the sculpture. The results turnt out to be very strong and stable.

Fabrication Procedure

Step 1: Single components

Fabrication Procedure

Step 2: First aggregation

Fabrication Procedure

Step 3: Second aggregation

Prototype Fabrication | Branching

Fabrication Procedure

Step 4: Sculpture

Fabrication Procedure

Step 5: Reinforced sculpture

[ Branching Prototype ] After aggregation, we applied concrete mixed with PVA powder on the surface of the model in order to strengthen and harden the sculpture. The results turnt out to be very strong and stable.

Physical Prototype

Feature 1:

Branching system provides infinite growing possibilities to form larger aggregation.

Close-up

Design Language

Feature 2:

Bundle system provides this whole object the structual meaning and gives it recognisable pattern.

Close-up

Prototype Fabrication | Branching

Top View

[ Twisting Prototype ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Close-up

Close-up

Side View

Prototype Fabrication | Bundles

Front View

[ Chair Fabrication ] We used 3 different sizes of cones for the chair fabrication. First started with seating part by using side connection, then building up the back part by branching with spiral pattern. Lastly, the legs part are the combination of linear stacking and spiral pattern.

Twist

Branch

Prototype Fabrication | Chair Fabrication

[ Chair Fabrication ] The diagram illustrates the design languages used in each part of our chair fabrication.

Side Connection

5 Angle

10 Angle

15 Angle

20 Angle

30 Angle

15 Angle Branching

Prototype Fabrication | Chair Fabrication

[ Components used in Chair Fabrication ] We used 3 different sizes of cones for the chair fabrication. Also the design languages such as side connection, branching, and stacking are used based on our research study. As a result we used the total of 510 cones to fabricate the whole chair.

Side Connection

5 Angle

10 Angle

Cone Size

S

6.00cm

3.00cm

-

8

4

-

7

10

13

4

4

3.00cm

M

8.00cm

Cone Size

Cone Size

L

8.00cm

4.00cm

Prototype Fabrication | Chair Fabrication

20 Angle

30 Angle

15 Angle Branching

Stacking

-

5

3

-

95

15

5

7

2

223

8

8

5

2

192

Total: 510 Cones

[ Chair Fabrication ] We used 3 different sizes of cones for the chair fabrication. First started with seating part by using side connection, then building up the back part by branching with spiral pattern. Lastly, the legs part are the combination of linear stacking and spiral pattern.

[ Chair Fabrication Process ]

Step 1

Step 2

Step 6

Step 7

Prototype Fabrication | Chair Fabrication

Step 3

Step 4

Step 5

Step 8

Step 9

Step 10

[ Concrete-spraying Process ] We used concrete spray technique instead of brushing on the surface. This technique used less time consuming, however the outcome is not as strong as brushing technique due to the fact that concrete spray can stick only onto the surface, while brushing, the concrete goes inside the cone which help strengthen the structure.

Step 1: Concrete Powder

Step 2: Add Water

Step

p 3: Mix Together

Prototype Fabrication | Chair Fabrication

Step 4: Pour concrete into spray gun

Step 5: Spray it on the chair

[ Concrete-spraying Process ] We used concrete spray technique instead of brushing on the surface. This technique used less time consuming, however the outcome is not as strong as brushing technique due to the fact that concrete spray can stick only onto the surface, while brushing, the concrete goes inside the cone which help strengthen the structure.

Prototype Fabrication | Chair Fabrication

[ Chair Fabrication ] We used 3 different sizes of cones for the chair fabrication. First started with seating part by using side connection, then building up the back part by branching with spiral pattern. Lastly, the legs part are the combination of linear stacking and spiral pattern.

Prototype Fabrication | Chair Fabrication

[ Stool Fabrication ] We used only one size of cones for the chair fabrication. First started with seating part by using side connection, then building up the back part by branching with spiral pattern. Lastly, the legs part are the combination of linear stacking and spiral pattern.

Twist

Branch

Prototype Fabrication | Chair Fabrication

[ Stool Fabrication ] We used only one size of cones for the chair fabrication. First started with seating part by using side connection, then building up the back part by branching with spiral pattern. Lastly, the legs part are the combination of linear stacking and spiral pattern.

Side Connection

Stacking

3

6

Stacking with rotation

Branching

Cone Size

L

8.00cm

4.00cm

10

5

Total: 140 Cones

Prototype Fabrication | Chair Fabrication

[ Stool Fabrication ] We used only one size of cones for the chair fabrication. First started with seating part by using side connection, then building up the back part by branching with spiral pattern. Lastly, the legs part are the combination of linear stacking and spiral pattern.

Prototype Fabrication | Chair Fabrication

Close-up

Close-up

Close-up

[ Stool Fabrication ] We used only one size of cones for the chair fabrication. First started with seating part by using side connection, then building up the back part by branching with spiral pattern. Lastly, the legs part are the combination of linear stacking and spiral pattern.

Prototype Fabrication | Chair Fabrication

CHAPTER

06

ARCHITECTURAL POTENTIAL For this part, we are trying to do a fundamental component reseach of the reasons why we chose the cone shape, the parameters of cones, the different curvature, the design language library.

Architectural Potential | Surface Study

CHAPTER

06

PART 1: SURFACE STUDY

[ Surface Pattern ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Step 1

Step 2

+

-

Step 3

+

+

Connection Option 1:

Stacking

+

+

-

Connection Option 2:

Side Interlocking

Surface C

Top View

Connection

w

Architectural Potential | Surface Study

Surface Connection

Top View

[ Surface Pattern ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Regular Surface Pattern

Option 1

Dense

Regular Su

Op

urface Pattern

ption 2

Architectural Potential | Surface Study

Regular Surface Pattern

Option 3

Sparse

[ Surface Pattern ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Surface Pattern Option 1

Step 1

Surface Pattern Option 1

Step 2

Surface Pattern Option 1

Top View

Architectural Potential | Surface Study

Surface Pattern Option 2

Step 1

Surface Pattern Option 2

Step 2

Surface Pattern Option 2

Top View

[ Surface Pattern ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Surface Pattern Design Step 1: Straight lines

Surface Pattern Design Step 2: Curvy lines

Surface Pattern Design Step 3: Blending the curves

Surface Pattern Design Step 4: Form a surface

Architectural Potential | Surface Study

Surface Pattern

Top View

[ Wall & Floor Study ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Linear element

+

Curvy element

=

Supporting spaceframe

Architectural Potential | Surface Study

Surface Study

Axonometric View

Surface Study

Front View

[ Wall Pattern ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Surface Pattern Design Step 1: Straight lines

Surface Pattern Design Step 2: Curvy lines

Surface Pattern Design Step 3: Gradient change

Surface Pattern Design Step 4: Create a surface

Architectural Potential | Surface Study

Surface Study

Axonometric View

Architectural Potential | Column Study

CHAPTER

06

PART 2: COLUMN STUDY

[ Column Study ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Column Study Step 1: Linear curves

Column Study Step 2: Radial range

Two-dimensional Column Study Step 3: Radial pattern

Column Study Step 4: Fluid pattern

3m X 3m Planer Surface

2D Plan

Architectural Potential | Column Study

3m

3m

3m

Three-dimensional 3m X 3m X 1.5m Frame

3m X 3m X 3m Module

3D Volumn

[ Column Study ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

+

Column Design Element 1: Regular bundles

Column Design Element 2: Irregular bundles

Architectural Potential | Column Study

=

Column Study

Axonometric View Column Study

Front View

[ Column Study ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

+

Column Design Element 1: Regular bundles

Column Design Element 2: Irregular Branches

Architectural Potential | Column Study

=

Column Study

Axonometric View Column Study

Front View

Architectural Potential | Staircase Study

CHAPTER

06

PART 3: STAIRCASE STUDY

[ Staircase Design ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Staircase Design Step 1: Staircase basic shape

Staircase Design Step 2: Staircase basic outline

Staircase Design Step 3: Staircase individual step

Staircase Design Step 4: Staircase basic geometry

Architectural Potential | Staircase Study

Staircase Step

Option 1

Staircase Step

Option 2

Staircase Step

Option 3

Staircase Step

Option 4

[ Staircase Design ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Staircase Design

Staircase Design

Staircase Design

Staircase Design

Iteration 1

Iteration 3

Iteration 2

Iteration 4

Architectural Potential | Staircase Study

Staircase Design

Iteration 5

[ Staircase Design ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Staircase Design

Element 1 Bundle Syetem

Staircase Design

Element 2 Branching Syetem

Architectural Potential | Staircase Study

Staircase Design

Front View

[ Staircase Design ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Staircase Design

Step 1 Planer surface

Staircase Design

Step 2 The first step

Staircase Design

Axonometric View

Staircase Design

Step 3 The second step

Staircase Design

Step 4 The thire step

Architectural Potential | Staircase Study

Staircase Design

Perspective View

Architectural Potential | Spcae Design

CHAPTER

06

PART 4: SPACE DESIGN

[ Modularlised Boxes ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

+

-

Connection Option 1:

Stacking

+

Connection Option 2:

Side Interlocking

+

+

+

+

-

+

Surface Connection

Top View

Architectural Potential | Spcae Design

Surface Connection

Axonometric View

[ Space Design ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Module Design

Element 1 Floor

Module Design

Element 4 Column

Module Design

Element 2 Ceiling

Module Design

Element 5 Staircase

Module Design

Element 3 Wall

Module Design

Element 6 Steps

Architectural Potential | Spcae Design

Space Design

Axonometric View

[ Architectural Scenario ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Architectural Potential | Spcae Design

[ Architectural Scenario ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Architectural Potential | Spcae Design

[ Architectural Scenario ] After the aggregation of the cones, again we applied concrete on the surface of the chair’s leg by brushing it on the aluminium mesh. The results turnt out to be very strong and stable.

Architectural Potential | Spcae Design

THE END

THANK YOU

C NEcrete

Team Members: Haibo Xiao | Liyuan Ma | Qiaochu Wang | Sanchutha Choomsai Tutors: Daniel Widrig | Soomeen Hahm | Igor Pantic | Stefan Bassing Research Cluster 6, MArch Architectural Design, 2015 - 2016 The Bartlett School of Architecture | UCL 2016.07