BPro RC6 2015/16_PINFILL

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]