PINFILL
TEAM MEMBERS | DUN YANG, ZIXUAN HUANG, HUAIRUI JING TUTORS| DANIEL WIDRIG, STEFAN BASSING, SOOMEEN HAHM, IGOR PANTIC RESEARCH CLUSTER 6, 2015-16 BARTTLET SCHOOLE OF ARCHITECTURE, UCL ARCHITECTURAL DESIGN
CONTENTS INTRODUCTION REFERENCES > Soft material inflation & pin >Inflation and deflation behavior > Wood construction INITIAL STUDIES > Material & fabrication tools > Possible combinations > Scale up > Design language exploration >Prototype design MATERIAL HARDEN EXPRIMENTS > Tests of different harden methods > Sawdust & glue experiments > Problems & Solution PIN LANGUAGE PIN LANGUAGE 1: DEFINING TEXTURE > pin forming the texture > texture deformation > resolution studies > pin on the volume & surface > prototype design
PIN LANGUAGE 2: DEFINING CURVE > pin forming the curve shapes > texture deformation > subdivision and aggregation AGGREGATION INITIAL STUDIES >single component repeat >multi components combine >multi components combine & repeat BASIC LOGIC FABRICATION PROCESS PROTOTYPE DESIGN >convave-convex form combine >interlocking structure with connecting joints >frame structure with connecting joints
REFERENCES [SOFT MATERIAL INFLATION]
1 3 2 4 1. Dancing Allowed Ernesto Neto 2. Dance Response Ernesto Neto 3. Nuds Sarah Lucas 4. Nud (24) Sarah Lucas
[CONCRETE FABRIC FORMWORK]
1 3 2 4 1-2. Farbic Formwork University of Edinburgh 3-4. FattyShell University of Michigan
REFERENCES [SOFT MATERIAL INFLATION & PIN]
SOFT MATERIAL PIN
1 2
1. Erotic Fetishes Cecile Dachary 2. P_Wall Andrew Kudless
PLASTER AND FABRIC STITCHING
1 2
1. Edge articulation AA DRL 2. Grompies AA DRL
INITIAL STUDIES [MATERIAL & FABRICATION TOOLS] We have tried infill with different scale, hardness and thickness, membranes with different transparency and elasticity.
INFILL TEXTURE
SOFT
HARD
SMALL
SAWDUST
RICE
BEAN
POLYESTER
CRYSTALS JELLY BALL
PEANUT
COTTON
FOAM
FOAM BALL
LARGE
PIN TOOLS
TECTORIAL MEMBRANE
SAFETY PIN
BALLOON
FABRIC
PRESS STUD
PLASTIC SHEET
LATEX
NEEDLE & THREAD
NYLON
LYCRA
INITIAL STUDIES [POSSIBLE COMBINATIONS] Variety types of try about different materials and pin tools. Pick out the better results for further studies.
＋ BEAN
＋ SAFETY PIN
＋ SAWDUST
＋ SAFETY PIN
＋ RICE
NYLON
NYLON
＋ SAFETY PIN
NYLON
＋ FOAM BALL
FOAM
＋ SAFETY PIN
＋ POLYESTER
NYLON
＋ SAFETY PIN
NYLON
＋ BEAN
PEANUT
BALLOON
INITIAL STUDIES [SCALE UP] Pinning or stitching could be a method to combine single elements or chunks.
NYLON + COTTON
SINGLE
DOUBLE
MULTIPLE
NYLON + SAWDUST
SINGLE
MULTIPLE
REFERENCES [WOOD BUILDING MATERIAL]
1 2 5 6 3 4 7 8 1-2. Plywood sheet 5-6. Oriented strand board manufacturing process (OSB) manufacturing process 3-4. ICD-ITKE Research Pavilion 7-8. Checkered Playroom University of Stuttgart Jingxiang Zhu
INITIAL STUDIES | Design Language Exploration [FORMING PROCESS]
The distribution of stitching points could trigger certain linear sunken on the surface, which is the basic logic for all the pinning behaviors.
INITIAL STUDIES | Design Language Exploration [SINGLE LINEAR-ITEM PIN STUDY] Pinning could be considered as a deformation tool that provide external constraint to a entity. That is condusive to generating a fluid curved surface as a response. The distance between two pinning points could decide the scale of the heave and the density of stitch imply the complexity.
PIN POINTS
PIN POINTS
2
4
2
4
6
MULTI
PIN POINTS
6
MULTI
INITIAL STUDIES | Design Language Exploration [TWO LINEAR-ITEMS PIN STUDY] Certain pinning method, such as diagonal pinning, could contribute to generating a series of spatial relationships like intertwine or parallel curves. Aggregation of different pinning strategy could give rise to unique pattern on the entity.
INITIAL STUDIES | Design Language Exploration [MULTI-ITEM PIN STUDY] We can also utilize the principle from previous study to create more complex items in bigger scale, then apply aggregation strategy to using these chunks for large scale construction.
INITIAL STUDIES | PROTOTYPE DESIGN [CHAIR DESIGN BASED ON MULTI-ITEM PIN STUDY]
AGGREGATION | INITIAL STUDIES [BRIDGE DESIGN: SINGLE COMPONENT REPEAT]
INITIAL STUDIES | PROTOTYPE DESIGN [COLUME DESIGN BASED ON LINEAR-ITEMS PIN STUDY] Columns design were done by aggregation of linear elements. This experiment could prove this design language, intertwine and weaving, is effective to create voids and structural parts.
INITIAL STUDIES | PROTOTYPE DESIGN [CHAIR DESIGN BASED ON LINEAR-ITEMS PIN STUDY] The processing script, which uses flocking agents and contain attractor points and repeller points, is controled by parameters. By adjusting the position and parameters, a series of weaving moments could be captured. After that, pinning and inflation engine could be introduced to generate variation and differentiation, which aims to add details and achieve structural optima .
MATERIAL HARDEN EXPERIMENTS
MATERIAL HARDEN EXPERIMENTS | TESTS OF DIFFERENT HARDEN METOHDS [TEST 1: RESIN+LATEX+SAWDUAT
SAMPLE
BEFORE: SAWDUST - MORE TO LESS (left to right)
AFTER
Manufacturing Difficulty Time For Hardening Price Structure Durability Maintaining Texture
A sawple to observe how resin flow in the sawdust bag, and a test about if sawdust amount influence the harden result.
RESULT: Resin harden too fast; Need latex bag for each component; Very high cost .
STEP 1 Make a vacuum bag and fill in sawdust. Stick pips at the ends.
STEP 2 Mix resin part A and B. One pipe stretch into resin, another one connect with vacuum pump.
STEP 3 Observe how resin flow through sawdust.
STEP 4 When finish, wait until it harden and remove pipes and latex bag.
MATERIAL HARDEN EXPERIMENTS [TEST 2: [VACUUM: SAWDUST MIXED WITH GLUE]
VACUUM SINGLE COMPONENT
RESULT: Generally have the same quality, but PVA is the cheapest glue. SAWDUST + 502 WOOD ADHESIVE 2:3
0
[SMALL STRUCTURE DESIGN]
RESULT: Vacuum process can form a structure, but lose the pin language at the same time. Surface also looks too rough.
SAWDUST + WOOD GLUE 1:1
SAWDUST + PVA 1:3
[TEST 3: [WITHOUT VACUUM: SETS OF EXPERIMENTS]
SAWDUST DIP INTO GLUE HARDNESS
60%
MAINTAINING TEXTURE
60%
MANUFACTURING DIFFICULTY
50%
MIXED: SAWDUST + GLUE
HARDNESS
65%
MAINTAINING TEXTURE
40%
MANUFACTURING DIFFICULTY
90%
MIXED: SAWDUST + POWDERED RESIN WOOD GLUE
HARDNESS
75%
MAINTAINING TEXTURE
65%
MANUFACTURING DIFFICULTY
75%
Sets of experiments without vacuum to provide pressure. Sawdust dip into glue is the most pure and easist way.
MATERIAL HARDEN EXPERIMENTS | TESTS OF DIFFERENT HARDEN METOHDS [THE RESULT OF HARDEN TESTS AND CASTING METHODS]
COVERING: RUBBER FILLING: SILICON+SAWDUST
COVERING: NYLON FILLING: WOOD GLUE + SAWDUST
HARDNESS
HARDNESS
CURING TIME
CURING TIME
COVERING: FABRIC FILLING: CONCRETE + SAWDUST
COVERING: NYLON + RESIN FILLING: SAWDUST
HARDNESS
HARDNESS
CURING TIME
CURING TIME
COVERING: LATEX FILLING: SAWDUST + RESIN
COVERING: NYLON FILLING: SAWDUST CASTING: PLASTER + WATER, 1:1
HARDNESS
HARDNESS
CURING TIME
CURING TIME
COVERING: NYLON FILLING: SAWDUST CASTING: CEMENT + WATER, 1:1
COVERING: NYLON FILLING: SAWDUST CASTING: PLASTER RESIN + WATER, 1:1
HARDNESS
HARDNESS
CURING TIME
CURING TIME
MATERIAL HARDEN EXPERIMENTS | SAWDUST DIP INTO GLUE TEST 6: [SAWDUST TYPE & DIFFERENT PINNING OBJECTS]
1 LAYER PIN
NORMAL SAWDUST
FINE SAWDUST
2 LAYERS PIN
2 ELEMENTS COMBINE PIN
MATERIAL HARDEN EXPERIMENTS | SAWDUST DIP INTO GLUE TEST 4: [PROPORTION OF GLUE AND WATER]
GLUE 100% WATER 0%
GLUE 75% WATER 25%
GLUE 50% WATER 50%
GLUE 25% WATER 75%
TEST 5: [DIPPING TIME] Based on the first test, dipping time were all considered as a factor. After balance the dipping time and dipping quality, 15 minutes might be the most properiate choice.
5 MINUTES
15 MINUTES
30 MINUTES
60 MINUTES
MATERIAL HARDEN EXPERIMENTS | PROBLEMS & SOLUTIONS [PROBLEMS FOR THE MATERIAL]
BEFORE HARDEN: FABRICK BROKEN
REASON: • Sewing didn’t done well • Fabric quality not good enough
• Too much force when pin
AFTER HARDEN: CRACK ON THE SAWDUST
REASON: • The structure is too heavy with glue
[SOLUTION: FABRIC WITH DIFFERENT DENIER] Thicker membrane can reduce the fabrication problems, and can produce very reach pinning texture, but the transparence will reduce and sawdust will be hard to see. Therefore, different membrane canbe use for specific purposes.
15 DENIER
Elastane Proportion Texture Visibility Fabric Toughness
100 DENIER
30 DENIER
6% - 11%
17 - 19%
17% - 23%
PIN LANGUAGE
PIN LANGUAGE: DEFINING TEXTURE [PIN FORMING THE TEXTURE] Stitching is the most flexible way to create pin points. Stitching according to different pattern could result variety sunken texture on the curved surface.
PIN LANGUAGE: DEFINING CURVE [PIN FORMING THE CURVE SHAPES]
SINGLE ELEMENT
TWO ELEMENTS
THREE ELEMENTS
PIN LANGUAGE: PINCH POINT GENERATION [ESSENCIAL PINNING METHODS]
To Deform
To Subdivide
PIN LANGUAGE: PINCH POINT GENERATION [LINEAR PINNING METHODS]
PIN LANGUAGE: PINCH POINT GENERATION [TRIDIMENTISONAL PINNING METHODS]
PIN LANGUAGE: DEFINING TEXTURE | INFLUENCE OF PINNING [SAME PIECE OF FABRIC + DIFFERENT AMOUNT OF SAWDUST]
3637g
2671g
1788g
899g
[SAME AMOUNT OF SAWDUST +DIFFERENT SIZE OF FABRIC]
MATERIAL HARDEN EXPERIMENTS :
| INFLUENCE OF PINNING
[STRUCTURE STRENGTH EXPLORATION]
STRENGTH
156.8N WEAK
186.2N
274.4N STRONGH
PIN LANGUAGE: DEFINING TEXTURE | PIN ON THE VOLUME & SURFACE [PIN OBJECT EXPANSION ]
VOLUME
SURFACE
AGGREGATION | FABRIC PIECE CUTTING [TAILOR CONTROL : IRREGULAR FORM]
AGGREGATION | FABRIC PIECE CUTTING [TAILOR CONTROL: 3D CUTTING]
[TAILOR CONTROL: LINEAR ELEMENTS CUTTING]
PIN LANGUAGE: DEFINING TEXTURE | RESOLUTION STUDIES [SMALL SCALE DESIGN]
PIN LANGUAGE: DEFINING TEXTURE | PROTOTYPE DESIGN [PIN ON THE SURFACE & SUBDIVISION]
PIN LANGUAGE: DEFINING TEXTURE | RESOLUTION STUDIES [LARGE SCALE DESIGN]
AGGREGATION
AGGREGATION | BASIC LOGIC [CONNECTING METHODS]
1. ACCORDING TO CONVAVE-CONVEX FORM
2. ACCORDING TO CURVE FORM
3. ACCORDING TO DESIGN CONNECTING JOINTS
AGGREGATION | FABRICATION PROCESS
STEP 1 Sub-divide the elastic fabric.
STEP 2 Vacuum process can form a structure, but lose the pin language at the same time. Surface also looks too rough.
STEP 3 Infill sawdust in to fabric bag.
STEP 4 Pin on the elements to form the shape.
STEP 5 Deep the finishied components into glue & water.
STEP 6 Hang the component with special direction for few days and wait for harden. Fan or heater can help accelerate this process.
AGGREGATION | PROTOTYPE DESIGN [STOOL: INTERLOCKING STRUCTURE WITH CONNECTING JOINTS] 2
“Y” FORM AGGREGATION TYPE 1
Design particular joint for each elements and ensure each part can interlock.
COMPONENTS
HARDEN SEQUENCE:
A. NO.1 AND NO.3
B. NO.2 AND NO.4
C. TOP SURFACE
CONNECTING METHODS [CONNECTING METHOD FOR LARGE COMPONENTS]
CONNECTING METHODS [LARGE COMPONENTS FABRICATION]
CONNECTING METHODS [LARGE COMPONENTS FABRICATION METHOD]
SPRAY GLUE AND WATER MIXTURE AFTER HANGING
AGGREGATION | PROTOTYPE DESIGN [STOOL: LOCKING STRUCTURE WITH CONNECTING JOINTS]
AGGREGATION | PROTOTYPE DESIGN [CHAIR: INTERLOCKING LARGE STRUCTURE DESIGN]
FRONT VIEW
TOP VIEW
AGGREGATION | PROTOTYPE DESIGN [CHAIR: INTERLOCKING LARGE STRUCTURE DESIGN]
TOP VIEW
FRONT VIEW
PERSPECTIVE VIEW
AGGREGATION | PROTOTYPE DESIGN [ARCH: LOCKING LARGE STRUCTURE DESIGN]
STRUCTURAL SYSTEM: SPRING DEFORMATION ONE LAYER
TWO LAYERS
TWO LAYERS
MUTIPLE LAYERS
STRUCTURAL SYSTEM: SPRING DEFORMATION [PROTOTYPE DESIGN: COLUMN]
SPRING SETUP
SPRING DEFORMATION
STRUCTURAL SYSTEM: SPRING DEFORMATION [PROTOTYPE DESIGN: COLUMN]
GUIDE CURVE
REBUILT CURVE
PIPED MESH
WITH TECXTURE
STRUCTURAL SYSTEM: SPRING DEFORMATION [PROTOTYPE DESIGN: COLUMN]
DIVIDE INTO SEVERAL PARTS
STRUCTURAL SYSTEM: SPRING DEFORMATION [PROTOTYPE DESIGN: COLUMN - FABRICATION]
STRUCTURAL SYSTEM: SPRING DEFORMATION [PROTOTYPE DESIGN: COLUMN - FABRICATION DETAILS]
STRUCTURAL SYSTEM: SPRING DEFORMATION [PROTOTYPE DESIGN: COLUMN]
STRUCTURAL SYSTEM: SPRING DEFORMATION [PROTOTYPE DESIGN: STAIRCASE]
guide frame
multiple curves
STRUCTURAL SYSTEM: SPRING DEFORMATION [PROTOTYPE DESIGN: SPACE DESIGN]
STRUCTURAL SYSTEM: SPRING DEFORMATION [PROTOTYPE DESIGN: SPACE DESIGN]