ROPOLOGY Research Cluster 6 Daniel widrig, stefan bassing, Soomeen hahm, Igor Pantic Jia-hao SYU, Aisha WANG, Lida ZHANG 05/07/2016
PROJECt Introduction Project ROPOLOGY aims to create self-supported rope structure by melting plastic rope. Instead of creating tensile structure, this project explores the potential of pressure resistance of plastic rope. The fabrication method of this project is layering continual ropes to make overlapping sinuous shape components which will then be slightly melted down to enhance the strength. Based on the fabrication methods and material research, this project creates a loop system containing three design languages: local loop component, global loop bundle and global surface. After the components are set up, bundles and surfaces of different functions will be added to connect the components and strengthen the whole structure. By utilizing this system from small scale prototypes to furniture, the project will eventually attempt to achieve the designs of large-scale architectural elements.
CONTENTS CHAPTER 1 fabrication > REFERENCE > INITIAL MODELS > fabrication methods > MATERIAL RESEARCH
CHAPTER 2 DESIGN LANGUAGE > Geometry study > component language > connection language > aggregation logic > Strengthening language > Combination
CHAPTER 3 WORKFLOW > Digital workflow > Physical workflow > Application
CHAPTER 4 optimization > Shortest path > longuage transformation
CHAPTER 5 proposal > Aggregation I > Aggregation II
CHAPTER 1 fabrication > Reference > Initial models > Fabrication methods > Material research
PROJECT DESCRIPTION | REFERENCE
[ Crocheting & Stitching ] [ Rope is the perfect material for bio-morphic forms. By using crocheting techniques and repeating one stitch in a strict mathematical progression, rope can be transformed into a largescale and self-supporting scuplture. ]
1 1,2 3
Rope Scuplture by Judy Tadman Rope Scuplture by Heather Pickwell
2
3
[ Casting ] [ By using different hardening methods such as applying resin or melting polyrope, soft and lightweight rope can become strong enought to bear heavy load. ]
1 1 2
Knot Chair by Marcel Wanders Meltdown Chair by Tom Price
2
PROJECT DESCRIPTION | INITIAL MODELS
[ Fabrication ] [ Different fabriction methods were tried in the initial study, from weaving knots to layering ropes. In order to make the model self-suported, layering will be the main method. ]
weaving knots
spatial curves
Layering
PROJECT DESCRIPTION | Fabrication
[ Freeform ] [ Making freeform components aims to find some shapes and moments which can be simulated in the digital study. ]
model A
model B
model C
PROJECT DESCRIPTION | Fabrication
[ Template ] [ In order to make the fabrication process more precise, template is introduced to the fabrication set up. In this way, different components can be assembled together precisely. ] basic geometry
metal pipe
3D printed joint
+
combination
template A
component A
template B
component B
template C
component C
PROJECT DESCRIPTION | MATERIAL RESEARCH
[ Rope Samples ] [ Project ROPOLPGY aims to make self-supported rope models by melting them instead of applying hardening coating such as resin. Therefore several rope samples were tested in order to find the right ones which can be melted and easily shaped. ]
Rope 1
Rope 2
Rope 3
Material
Cotton
Synthetic Sisal
Polypropylene
Thickness
10mm
10mm
10mm
Hardness Shaping Melting point Price
180oC ~190oC
175oC ~180oC
Rope 4
Rope 5
Rope 6
Polyester
Polyester
Polyester
10mm
8mm
10mm
250oC ~260oC
170oC ~175oC
170oC ~175oC
PROJECT DESCRIPTION | MATERIAL RESEARCH
[ Thermal Test ] [ Heat gun was introduced to melt the rope. The rope will first be covered by tinfoil and held by metla wires to reduce the deformation during heating. Plaster was also applied on the surface of the model to keep the shape.]
COVERING MATERIAL
tinfoil
ORIGINAL
metal wire
HEAT GUN temperature range: 330oC & 560oC plaster
IGINAL MODEL
MELTED BY HEAT GUN
OUTCOME
The surface is harsh after melted by heat gun.
Plaster is heat-insulated which completely prevents the melting process.
Plaster is heat-insulated which completely prevents the melting process.
PROJECT DESCRIPTION | MATERIAL RESEARCH
[ Thermal Test ] [ After testing with heat gun, following the similar cover technique, rope samples were baked in oven which can provide evener heat. ]
COVERING MATERIAL
tinfoil
ORIGINAL
metal wire
sand OVEN temperature range: 90oC ~230oC
sand
&
plaster
mixture
IGINAL MODEL
BAKED IN OVEN
OUTCOME
The surface is smoother comparing with the one melted by heat gun.
The rope is completely melted down and messy since the sand is loose.
The rope is barely melted down after covered by mixture of plaster and sand.
PROJECT DESCRIPTION | MATERIAL RESEARCH
[ Thermal Test ] [ Several simple rope models were tested under different heating methods. This aimed to find the right temperature and casting method which can be applyed on the next step. ]
polyethylene rope
Before
A. heat gun
+
tinfoi
After B. oven
+
tinfoil
Casting Method
A
Sand: Plaster: Water C. oven
+ sand, plaster, water mixture
C 20 : 1 : 2
Time
10 mins
30 mins
Temperature
500oC
210oC
Hardness Deformation
C
B
C
C
20 : 1 : 2
30 mins
10 : 1 :1
1:0:0
30 mins
30 mins
30 mins
30 mins
220oC
210oC
230oC
220oC
PROJECT DESCRIPTION | MATERIAL RESEARCH
[ Thermal Test ] [ These images show the result of thermal test samples which were baked in oven. ]
synthetic sisal rope ( polyethylene )
Before
wrap with tinfoil After
baked in oven
Temperature
210oC
220oC
Time
20 mins
20 mins
Hardness Deformation
poly rope ( polypropylene )
230oC
210oC
220oC
230oC
20 mins
30 mins
30 mins
30 mins
PROJECT DESCRIPTION | MATERIAL RESEARCH
[ Thermal Test ] [ These images show the result of thermal test samples which were baked in kiln. ]
synthetic sisal rope ( polyethylene )
Before
wrap with tinfoil After
baked in kiln
Temperature
300oC
350oC
Time
30 mins
30 mins
Hardness Deformation
poly rope ( polypropylene )
350oC
350oC
350oC
400oC
40 mins
15 mins
20 mins
15 mins
PROJECT DESCRIPTION | MATERIAL RESEARCH
[ Hardness Test ] [ The less deformed thermal test samples are placed under the pressure of a 2kg object. It is noticed that several samples barely deformed under the pressure. The other samples also become harder while comparing with the original ones. ]
Sample
Before
After
Weight Deformation (under pressure)
2 kg
2 kg
2 kg
2 kg
2 kg
2 kg
PROJECT DESCRIPTION | MATERIAL RESEARCH
[ Deformation & Shrink ] [ The samples always deformed and shrinked significantly after heated, which is inevitable. These images show the comparison between samples before and after heated. The blue dotted lines are the shapes of the original samples.]
Before
After
PROJECT DESCRIPTION | MATERIAL RESEARCH
[ Welding Ropes ] [ In order to avoid strong deformation, soldering gun is introduced. Soldering gun can be used in welding the ropes which can hardern the components to some extent. If stronger components are needed, they will be baked in oven in low temperature to avoid strong deformation. ]
thermal test
Sample
soldering gun welding
soldering gun welding + baked in oven
soldering gun
Harderness
welding ropes Weight Deformation (under pressure)
2 kg
2 kg
same components test
large components test
Before
soldering gun welding + baked in oven
After
soldering gun welding + baked in oven
PROJECT DESCRIPTION | MATERIAL RESEARCH
[ Prototype ] [ Series of components were welded by soldering gun. Components with high density are placed in the bottom part while those with less density are placed on the top. ]
top
bottom
prototype without bundles
PROJECT DESCRIPTION | MATERIAL RESEARCH
without bundles
with bundles
adding bundles
PHYSICAL TOOLS | TEMPLATES
[ Soldering Dot ] [ Instead of using glue gun as main tool for connectiong each rope surface, the soldering would be the alternative way to achieve the same goal. ]
Constraint points
+
PHYSICAL TOOLS | TEMPLATES
[ Bake Template ] [ In order to avoid deformation after baking in the oven, bake template is introduced to the baking set up. In this way, component could be hanged on the peak of the hook, which is use as constraint, while baking. ]
+
outcome
+ Temperature
220oC
Time
30 mins
Hardness
Deformation
PHYSICAL TOOLS | TEMPLATES
[ Heat Template ] [ In order to avoid deformation while heating, constraint template is introduced to the heating set up. In this way, component could be constrainted by the cone shape template. ]
metal sheet slide x 1 beam x1
+
+
outcome
Temperature
350oC
Time
20 mins
Hardness
Deformation
PHYSICAL TOOLS | TEMPLATES
[ Metal Template ] [ In order to avoid deformation when baking in the oven, metal template is introduced to the baking set up. In this way, component could be fixed while stucking in the each cylinder cones, which is use as constraint.]
M8 x 70mm Threaded Rod
M8 x 20mm Threaded Nut
115mm Aluminium Cylinder Cone
Three sides Steel Pyramid
[ Weld folded pyramid ]
3mm
The weld edges after folded
CHAPTER 2 design language > Geometry study > component language > connection language > aggregation logic > Strengthening language > Combination
DESIGN LANGUAGE | Geometry study
[ geometry selection ]
+
Triangular Pyramid
Rectangular Pyramid
C
Cube
Cuboctahedron
Icosahedron
DESIGN LANGUAGE | component language
[ Geometry-curve ] Control point curve
The following diagram tells the order of looping a singleline component with nurbe curve using the pyramid Wvertexes as control points.
triangular pyramid
control point
>
1
>
Process
2
3
>
1
1 loop
2 loop
3 loop
Result
DESIGN LANGUAGE | Geometry study
[ Geometry-curve ] Control point curve
rectangular pyramid
1 loop
2 loop
3 loop
Result
DESIGN LANGUAGE | Geometry study
[ Geometry aggregation ] Method i : Using adding strategy to find form.
assembling
adding
Method iI : Using CULLING SYSTEM to find form.
Guide curve
Culling geometry
DESIGN LANGUAGE | component language
[ logic ] Logic a Single line loop
Component a 2 rectangular pyramids
Component b 1 triangular pyramid+ 2 rectangular pyramids
Component c 2 triangular pyramids+ 1 rectangular pyramids
Logic b
Logic c
Logic d
Same size and density loop
Fullfilled loop
Logic a + Logic b
DESIGN LANGUAGE | component language
[ Local loop component catalog ] This page lists several possibilities of basic local loop components and mega local loop components with middle density.
Geometry a
Geometry b
Geometry c
Geometry d
DESIGN LANGUAGE | connection language
[ global bundle ] Method i : bundle Replacement according to the subdivision with the same organized form
Original size
Original size + Subdivided size
metthod ii bundle generating from seeds to Goal seeds with the different random form
Frame 1 Frame 1
Seed 1
Goal seed 1
Goal seed 2
Seed 2
Goal seed 2
Goal seed 1
seed 1
seed 2
Frame 2
DESIGN LANGUAGE | Aggregation logic
[ process decomposition ]
This diagram shows the process of two types of components connect to each others and aggregate with bundle layer added based on the frame.
+
2 types of basic components
Single-line component Offset by 4
rotate 1800
Combination
connection
DESIGN LANGUAGE | Aggregation logic
[ process decomposition ]
The following diagram shows the complexity of loop components based on twogeometry combinations, generating a type of ‘attachment’ in between basic components and bundles.
Global loop
Combination
Aggregation
DESIGN LANGUAGE | Aggregation logic
[ process decomposition ]
Original aggregation Small-scale Global loop
+
Large-scale Global loop
Final aggregation
DESIGN LANGUAGE | Strenghthening language
[ Surface ]
METHOD I : Fullfilled loop
Fullfilled loop components are strong surface based components made with high density loops.
Geometry a
Geometry b
Prototype a
Prototype b
DESIGN LANGUAGE | Strenghthening language
[ Surface Catalogue ]
METHOD II : Tween curve surface
Surface based components have the same idea with fullfilled loop of creating strong surfaces inside geometries to form structures in a whole systerm with more free style.
Geometry a
Prototype a
Prototype b
DESIGN LANGUAGE | Strenghthening language
[ Surface fabrication ]
original model
metal wire holding the gaps
metal sheet holding the shape
heated by heat gun
outcome
DESIGN LANGUAGE | combination
[ Loop + Surface ]
Prototype a
Prototype b
DESIGN LANGUAGE | combination
[ loop + global loop + Surface ]
Prototype a
Prototype b
CHAPTER 3 WORKFLOW > Digital workflow > Physical workflow > Application
WORKFLOW | DIGITAL workflow
[ chair analysis ]
Geometry a
Geometry b
+
Subdivision
This chair is made of the two types of basic pyramids triangular pyramid and rectangular pyramid. A frame with hierarchy is designed firstly and components are input into each geometry according to the subdivision. Two layers are generated inside this chair frame: Component layer and Bundle layer. Components have two sizes according to the frame while bundles are made to connect them as the structure.
bundle LAYER
+
+
middle-SIZE
+
component LAYER
+
SMALL-SIZE
WORKFLOW | DIGITAL workflow
[ chair analysis ]
Component list
Middle-size component
Small-size componentWW
Mega component
> Front view
> side view
WORKFLOW | DIGITAL workflow
[ chair catalog ]
These four chairs based on the loop logic and show the increasing density with different layers: small-size loop component layer, middle-size loop component layer, global loop layer and surface-based layer.
[ 1 layer ] > Global loop
[ 2 layers ] > Middle-size component > Global loop
[ 3 layers ] > Small-size component > Middle-size component > Global loop
[ 3 layers ] > Small-size component > Middle-size component > Surface
WORKFLOW | physical workflow
[ Fabrication ] The physical chair are made according to the aggregation logic with templates combining local loop components and global loop components. This page shows the chair.
Back part
Seat part
Basic component
Component
assembling
WORKFLOW | Application
[ Stool assembing ]
Bundle layer
+
Component layer
WORKFLOW | Application
[ Stool strengthening ] Subdivsion_1
> middle-size component
Subdivsion_2
> middle-size component > small-size componen
WORKFLOW | Application
[ Bench ]
Large-size component
Small-size component
Global loop
Middle-size component
WORKFLOW | Application
[ Bench ]
WORKFLOW | Application
[ Bench ]
WORKFLOW | Application
[ Column ] Local loop component + Global bundle
Column a
Column b
Column c
WORKFLOW | Application
[ Assembling ]
Component
Global loop
Component
Global loop_1
Global loop_2
WORKFLOW | Application
[ Column ] Local loop component + Surface connection
Surface
Surface + Local loop component
WORKFLOW | Application
[ Surface ] Surface function : bench seat
WORKFLOW | Application
[ Surface ] Surface function : bench seat Connection between components
CHAPTER 4 OPTIMIZATION Pattern study language utilization
Optimization | Language utilization
[ Study of density ] Method i : Based on the density of each component
Grid 1 layer
2 layers
5 layers
9 layers
Method iI : Based on the scale of the component
Grid with subdivision
Size 1
Size 2
Optimization | LANGUAGE TRANSFORMATION
[ Language transformation ]
Local loop components
Glob
bal bundle
Surface
Optimization | LANGUAGE TRANSFORMATION
[ Language combination ]
Global bundle_3
Global bundle_2
Global bundle_1
Small-size component
Middle-size component
Optimization | LANGUAGE TRANSFORMATION
[ prototype ]
Ad
Prototype with density using same size of components
dd bundles
Using global bundles to connect different components
OPTIMIZATION | PATTERN STUDY
[
[ Pattern Study ] [ In order to find a proper form and pattern, this triel firstly scale the basic geometry up to architectural space, then cull pattern out from the component grid by using basic loop curve as guide curve. In meanwhile, the subdivision level of component is depends on the distance, the closer the component to the guide curve, the more dense it becomes.]
[
[ Geometry]
+ [ Cull pattern ]
+
=
[ Distance ]
[ Density ]
0
Unit: mm
200
OPTIMIZATION | PATTERN STUDY
[ Pattern Study ]
[
[ In order to find a proper form and pattern, this triel firstly scale the basic geometry up to architectural space, then cull pattern out from the component grid by using basic loop curve as guide curve. In meanwhile, the subdivision level of component is depends on the distance, the closer the component to the guide curve, the more dense it becomes.]
[
[ Cull pattern ]
[ Distance ]
[ Density ]
0
Unit: mm
200
CHAPTER 5 PROPOSAL Aggregation I Aggregation II
Proposal
[ Aggregation i ] Process
Guide curve
Subdivision_2
Form+Subdivision_1
Small-size component
Middle-size component
Local loop component +
Global bundle Global connection
Surface
Proposal
[ Aggregation i ]
Proposal
[ Aggregation ii ]
Process Load
extract
F2 F1
Proposal
Guide
culling g
+
Overall form
Guide
subdivis
e curve i:
geometry
insert
cull
+
e curve iI:
sion
12m x 18m X 6m grid
geometry aggregation
Proposal
[ Structure analysis ] load structure high density / two sizes of components
stair high density
fRame siZe: 500mm(side length)
Celin light / low density / large-size component
fLOOR 1 laid down on a hill connecting the stair
fRame siZe: 250mm(side length)
/ small-size component
Proposal
[ Bundle generating ]
80 COHESION
40 ALIGNMENT
30 SEPERATION
0.5 SEPERATION
1.0 COHESION
1.5 ALIGNMENT
Shortest Path
20 AGENTS
30 SEEDS
30 GOALSEEDS
Longest Path
4 AGENTS
3 SEEDS
3 GOALSEEDS
Proposal
Proposal
WORKFLOW | digital workflow