Bartlett BPro RC9 2017/18_iBrick by SoomeenHahm Design

iBrick

MARCH ARCHITECTURAL DESIGN 2017-18 THE BARTLETT SCHOOL OF ARCHITECTURE | UCL

RC9 2017-18

Research Cluster 9

TUTOR SOOMEEN HAHM, ALVARO LOPEZ RODRIGUEZ MEMBER KAIJIE QIAN, SHENG LI, XIAO LIU

iBrick

Intelligent adaptative configuration RESEARCH CLUSTER 9 SoomeenHahm, Alavaro Lopez iBrick Sheng Li, Kaijie Qian, Xiao Liu

TUTOR SOOMEEN HAHM ALVARO LOPEZ RODRIGUEZ MEMBER KAIJIE QIAN SHENG LI XIAO LIU

TABLE OF CONTENTS

[ INITIAL TEST ]

01 MATERIAL TEST · Reference

· Foam & Erosion · Erosion Test

· Casting Material Test · Erosion Texture Test · Fabrication Work

02 GENERATIVE DESIGN · Fluid Simulation

· Chair Design

03 Augmentation REALITY · Workflow

· Kinect & Projector · Component

[ IBRICK ]

04 COMPONENT DESIGN · Material Test

· Component Design · Assembling System

· Combinational Possibilities

05 GENERATIVE DESIGN

· Logic Of Travelling Salesman

· Simulation Outcomes · Architecture propsal

· Generative Development

06 Augmentation REALITY · Hologram

· Interface

· Assembling Test · Re-assemble

· Tracking System

· Computer Thinking

07 ARCHITECTURE DESIGN · Site Analysis

· Architectural Proposal

[ PROPOSAL]

INTRODUCTION We investigate the additive and subtractive fabrication in the process of manufacturing to reduce waste of resources with the assisted of composite digital skills. The researches show that machine could improve the efficiency of manufacturing, especially in the complex cases. The machine could do interaction according to the changing environment. By applying machine learning to simulating structural performance, further energy savings can be attained. Furthermore, mixed reality is significant in this project. It could assist human to do very complex work which might be extremely difficult for machine based on the technologies recently. The experiments will be designed to demonstrate that combined fabrication could be used to manufacture stronger and more efficient architectural components. We will focus on situated mixed reality technology to visualize the digital proposal during the making process, guiding the fabrication of the physical model. The construction industry has been criticized as one of the major greenhouse gas emitters and a relatively unregulated sector. We believe that application of our research can better equip construction teams to diminish waste, and therefore decrease carbon emissions. Visualising construction sequencing using MR can also bring many other benefits like energy consumption, high quality and decreased the managerial risks. Therefore, it is significant to study on this field to save energy.

[ INITIAL TEST ]

Material Test Generative Design Augmentation Reality

REFERENCE

A projector-guided sculpture system by Christopher Skeels and projector-guided painting by Matthew Flagg are interactive cameraprojector system that augments the traditional artists to do artistic works with visual guidance directly. For example, the artist in Shapeshift use Kinect to scan the initial geometry and use projector to project colour which has been calculated by computer. The camera can guide the artist to carve the initial sculpture to target geometry real-time, which makes the physical sculpture more accurately.

ShapeShift: A Projector-Guided Sculpture System Christopher Skeels and James M. Rehg 2017

Projector-Guided Painting Matthew Flagg and James M.Rehg 2015

INITIAL TEST [ FOAM & EROSION ] There are many ways to carve the Styrofoam. As it shown below, the erosion is hard to control but it could form various textures. The hot wire cutter is the most fastest method to cut the foam. Besides, machine cutting and CNC are more precious than others.

Erosion Preciseness: Time: Type:

Hot Wire Cutter Preciseness: Time: Type:

Saw Bench Preciseness: Time: Type:

CNC

Preciseness: Time: Type:

INITIAL TEST [ FOAM & EROSION ]

INITIAL TEST [ EROSION TEST ] There are a lot of differences in erosion process with different chemicals. In this part, we test many chemicals to erode the same styrofoam with the same quantity. As it shown, the different chemimcals cause the different texture of erosion.

Nail Polish Remover Erosion Time: Direction: Speed:

PVA Glue Erosion Time: Direction: Speed:

White Sprite Erosion Time: Direction: Speed:

Acetone Erosion Time: Direction: Speed:

Plastic Weld Erosion Time: Direction: Speed:

UHU Glue Erosion Time: Direction: Speed:

Sesame Oil Erosion Time: Direction: Speed:

502 Wood Adesive Erosion Time: Direction: Speed:

Vegetable Oil Erosion Time: Direction: Speed:

Super Glue Erosion Time: Direction: Speed:

Propylene Erosion Time: Direction: Speed:

Alcohol Erosion Time: Direction: Speed:

INITIAL TEST [ EROSION TEST ] To control the depth of erosion accurately, we observed different results by different dose of acetone from 1 drop to 5 drops. At the same time, we compared the depths during processing and after. We found the depth grows like the shocking wave and the 2nd erosion will not be affected even the 1st corrosion is still processing.

1 TIME

1 ML EACH TIME

2 ML EACH TIME

3 ML EACH TIME

4 ML EACH TIME

5 ML EACH TIME

2 TIMES (after dry)

3 TIMES (after dry)

4 TIMES (after dry)

2 TIMES (half dry)

3 TIMES (half dry)

4 TIMES (half dry)

INITIAL TEST [ CASTING MATERIAL TEST ] Casting material plays an important role in the project. For example, the fluidity and the speed of solidification would influence the result. Therefore, many materials are adopted into experiments and mixed with different binder to solidify the materials themselves. It turns out that the mixture of magnesium oxide and sand with the solution of magnesium chloride is the best formulation.

Shape:

Block

Price: Strength: Dry time:

Sand & Cement 1 : 1

Shape:

Block

Price: Strength: Dry time:

Sand & Plaster 1 : 1

Shape: Price: Strength: Dry time:

Sand & Miture(C&P) 1 : 1

Block

Shape:

Block

Broken pieces

Shape:

Price:

Strength:

Dry time:

Sand & Cement 2 : 1

Sand & Cement 3 : 1

Shape:

Block

Shape:

Block

Shape:

Price:

Strength:

Dry time:

Sand & Plaster 3 : 1

Shap:

Broken pieces

Sand & Plaster 4 : 1

Shape:

Block

Shape:

Price:

Strength:

Dry time:

Sand & Miture(C&P) 3 : 1

Block

Sand & Cement 4 : 1

Price:

Sand & Plaster 2 : 1

Sand & Miture(C&P) 2 : 1

Shape:

Sand & Miture(C&P) 4 : 1

Block

Shape:

Block

Price: Strength: Dry time:

Sand & Jesmonite 1 : 1

[ SELECTED ITEM ]

Shape:

Sand & MgO (MgCl2) 4 : 1

Shape:

Block

Price:

Strength:

Dry time:

Broken pieces

Sand & MgO (H2O) 1 : 1

Shape: Price: Strength: Dry time:

Sand & MgO (MgCl2) 1 : 1

Block

Shape:

Block

Shape:

Price:

Strength:

Strength：

Strength:

Dry time:

Sand & Jesmonite 2 : 1

Sand & Jesmonite 3 : 1

Shape:

Block

Sand & Jesmonite 4 : 1

Shape:

Broken pieces

Shape:

Broken

Price:

Strength:

Strength：

Dry time:

Sand & MgO (H2O) 2 : 1

Sand & MgO (H2O) 3 : 1

Shape:

Sand & MgO (MgCl2) 2 : 1

Shape:

Broken pieces

Sand & MgO (H2O) 4 : 1

Shape:

Block

Shape:

Price:

Strength:

Dry time:

Sand & MgO (MgCl2) 3 : 1

Sand & MgO (MgCl2) 4 : 1

Block

MgO+Sand 1:1

MgO+Sand 2:1

Plaster+Fibre

Sand & MgO + MgCl2 : 6.7 Kg

Plaster+Paper

Pure Plaster

Cement+Sand

Cement+Fibre

Cement+Sand+Fibre

Pure Cement

Pure Cement : 4.0 Kg

Pure Plaster : 5.8 Kg

Plaster + Glass Fibre : 4.9 Kg

Cement + Sand : 3.3 Kg

Cement + Sand + Fibre : 2.6 Kg

INITIAL TEST [ EROSION TEXTURE TESWVT ] The texture of eroded foam by acetone is very similar to Chinese porcelain. To imitate this facade, we used the solution of acetone and dissolved foams to smear on different test materials and made a crystal-clear coating.

Cement

Plaster

Jesminater

Sand+ magnesium oxide+ magnesium chloride

INITIAL TEST [ EROSION TEXTURE TEST ] To observe the binding of foam and casting material, we test different shape of foams as models, casted different materials and corroded the foam after it was dry and checked their textures.

DETAILS

Styrofoam + Plaster

Foam Board + Plaster

Styrofoam + Foam Board + Plaster

Styrofoam + Sand (MgO)

Styrofoam + Cement

Styrofoam + Plaster

TEST 1: DIFFERENT FOAM & PLASTER

Styrofoam + Plaster

Foam Board + Plaster

Styrofoam + Foam Board + Plaster

TEST 2: STYROFOAM & DIFFERENT CASTING MATERIALS

Styrofoam + Sand (MgO)

Styrofoam + Cement

Styrofoam + Plaster

INITIAL TEST [ FABRICATION WORK ] To build a 2.5d or a 3d model, acrylic plates were snipped into the certain shape and attached to each side of the bounding box. The plates were to restrict the part where the foam will be corroded. After all bounding boxes linked together, a 2.5d curved inter link was presented.

INITIAL TEST [ FABRICATION WORK ] To develop the current model into 3d, there are 3 connection surfaces, two of which can form a tunnel on one bounding box. We built a structure containing one, two, three tunnels as base components and form a 3d model by linking those components via connection surface.

INITIAL TEST [ FABRICATION WORK ]

[ GENERATIVE DESIGN]

· Fluid Simulation · Chair Design

INITIAL TEST [ GENERATIVE DESIGN ]

[ Fluid Simulation ]

Magnitude: 5

Magnitude: 15 Turbulence

Magnitude: 5

Magnitude: 15

Magnitude: 25

Magnitude: 30

Magnitude: 40

Vortex

Drag

Magnitude: 25

Magnitude: 30

Magnitude: 40

Turbulence

Vortex

Drag

INITIAL TEST [ GENERATIVE DESIGN ]

[ Fluid Simulation ]

Turbulence & Vortex

Turbulence & Drag

Vortex & Drag

Magnitude: T: 10, V: 05

T: 05, V: 05

T: 25, V: 05

T: 15, V: 05

T: 05, V: 15

T: 35, V: 05

T: 20, V: 10

T: 15, V: 15

T: 45, V: 05

T: 20, V: 30

T: 20, V: 05

Magnitude:

Turbulence & Vortex & Drag

T: 05, V: 0.5, D: 05

T: 15, V: 05, D: 10

T: 15, V: 10, D: 05

T: 30, V: 10, D: 15

INITIAL TEST [ GENERATIVE DESIGN ]

[ Fluid Simulation ]

Turbulence & Vortex

Turbulence & Drag

Vortex & Drag

Magnitude: T: 10, V: 05

T: 05, V: 05

T: 25, V: 05

T: 15, V: 05

T: 05, V: 15

T: 35, V: 05

T: 20, V: 10

T: 15, V: 15

T: 45, V: 05

T: 20, V: 30

T: 20, V: 05

Magnitude:

Turbulence & Vortex & Drag

T: 05, V: 0.5, D: 05

T: 15, V: 05, D: 10

T: 15, V: 10, D: 05

T: 30, V: 10, D: 15

INITIAL TEST [ GENERATIVE DESIGN ]

[ Fluid Simulation ]

1 Emitter:

2 Emitters:

3 Emitters:

Turbulence & Vortex

Turbulence & Drag

Vortex & Drag

T: 45, V: 05

T: 20, D: 10

T: 05, D: 15

Turbulence & Vortex & Drag T: 15, V: 05, D:10

INITIAL TEST [ GENERATIVE DESIGN ]

[ Fluid Simulation ]

1 Emitter:

2 Emitters:

3 Emitters:

Turbulence & Vortex

Turbulence & Drag

Vortex & Drag

T: 45, V: 05

T: 20, D: 10

T: 05, D: 15

Turbulence & Vortex & Drag T: 15, V: 05, D:10

INITIAL TEST [ CHAIR DESIGN ] Take an equilateral hexahedron in a cuboid and stack to the target shape. After drawing the structure line, snap it to the edge of the hexahedron. Determines the thickness of the structure according to the topology optimization. Cut structures out of original foam, assemble and cast it, erode unnecessary foam after that.

Component design

Aggregation

Snapping

Erosion Process

INITIAL TEST [ CHAIR DESIGN] During modeling, it was found that the eroded foam has a variety of features that can be used for many purposes. The smooth and hard part can be used for coating, and the hard, rough part can be used for supporting.

Coating Hard and Smooth

Supporting Hard and Rough

Attaching Fragile but Variety

Mold

INITIAL TEST [ CHAIR DESIGN ]

[ Augmentation Reality]

· Workflow · Kinect & Projector · Component

INITIAL TEST [ WORK FLOW ] After designing the proposal, we stack bounding boxes and use the Kinect, which has been connected to computer, to scan the physical model real-time. Through this method, the information of physical model will be input digitally and we colour the scanned geometry by calculation real-time. By projecting the colour on physical model, we can know which part should be removed and which part should be remained, compared with target geometry. Bounding Box Design

Casting

Kinect

Physical Model

Scan

Design Proposal

Generate Particles

Shoot Colour to the Physical Model to Guide the Subtractive Fabrication

Generate Colour

INITIAL AUGMENTED REALITY [ WORK FLOW ] Putting the Kinect on the top of physical model, we can get the scanned geometry digitally. After calculating the relationship between scanned geometry and target geometry, we project the colour on physical model to guide our erosion process real-time, which allows us to control the erosion part precisely.

INITIAL AUGMENTED REALITY [ KINECT & PROJECTOR ] We use kinect to scan the physical model. The kinect could establish the connection between the physical and digital model. The kinect could read the every change on real time. So we could do the interaction with the digital model. In this project, we use the acetone to erode the styrofoam according the guidness of the colour. The colour have different meanings. The red means that these areas should be eroded.

We set a bounding box, and put the target geometory inside of it. The computer will calculate the distance between the surface of the target model and bounding box. If the distance is far, i t w i l l s h o w r e d c o l o u r. Otherwise, the blue will appear. The kinect read the physical model and build the digital points to show the physical model. The projector will shoot the colour on the surface of the physical model to guide the fabrication.

INITIAL AUGMENTED REALITY [ KINECT & PROJECTOR ] The colour represent the erosion part. The warmer the more should be eroded. Therefore, during this process, we should erode the red part. Under this guide, we can cantrol the erosion part more or less.

INITIAL AUGMENTED REALITY [ COMPONENTS ] At the beginnig, we want to use the chemical to erode the styrofoam to form the special texture and shape. But after several tests, we can not control the erosion preciously. So, we cut the foam into the certain shape. We use the component to assemble the model.

The erosion is limited by many factors. The chemical is liquid. We can not control the gravity and the erosion texture preciously. So we want to control the fabrication process. We are interested in the interaction between the physical and digital model. So we chop the styrofoam into the same component. we utilize the component to assemble the initial geometry. Then, the 'erosion' process is taking the component out. The kinect will read the change on real time. The projector could shoot the colour change according to the digital mesh.

[ IBRICK ]

路路路路

Component Design Generative Design Augmentation Reality Architecture Proposal

[ COMPONENT DESIGN ]

路路路路

Material Test Component Design Assembling System Combinational Possibilities

COMPONENT DESIGN [ MATERIAL TEST ] Timber is a good material for our system. Basically, for our system, we want to use the timber to make the components and assemble with the interlock. We test oak, tulip, pine and beech. The beech timber is the best one for our project.

White Foam (Soft)

Styrofoam (hard)

As we turn into the assembling system with the components, there is no need to use the styrofoam. The main idea about our project is the interraction between the physical and digital model. So, we want to find the appropriate material for our system.

Tulip

Pine

Beech

Oak

Hardness Frangibility Growth Cycle Price Crack Density

39-47 lb/ft3

22-35 lb/ft3

32-56 lb/ft3

37-56 lb/ft3

COMPONENT DESIGN [ COMPONENT DESIGN ] Here is the evolution of the component. Ideally, we want to design the simply geometry of the component. And we also want to have a very simply method to lock the component. Therefore, we decide to utilize the dovetail shape to lock the components.

Tulip

Pine

Beech

Oak

COMPONENT DESIGN [ COMPONENT PARAMETERS ] We deisgn three different scales of components. The size of the section is the same, but the length is different. The concept is to apply the different scales into different function.

120

240

360

3 different scales

COMPONENT DESIGN [ COMBINATIONAL POSSIBILITIES ] Because of the three different scales of component, there are many different connections. Every component has six surfaces. They could be connected in many ways. Here is the possibilities.

COMPONENT DESIGN [ ASSEMBLING SYSTEM ]

The different ways to slide to lock the components.

[ GENERATIVE DESIGN ]

路路路路

Logic Of Travelling Salesman Simulation Outcomes Architecture propsal Generative Development

INITIAL GENERATIVE DESIGN [ LOGIC OF TRAVELLING SALESMAN] At the begainning, we focus on the logic of salesman to generate the object. Here is the concept of the logic.

We set the different start and end point, the algorithm will calculate the different path.

INITIAL GENERATIVE DESIGN

Timber Sticks

Assembling Process

Put the Glue Sticks

Components

INITIAL GENERATIVE DESIGN [ SIMULATION OUTCOME ]

[ The process of generating ]

[ Component ]

We want to use the most simplest componets to build the complex generative model with the help of the hololens. Therefore, after generating, we will simplify the model which could be built by several basic components.

INITIAL GENERATIVE DESIGN [SIMULATION OUTCOME Baed on the algorithm showed before, we can generate the shape. Then we utilize the simple and basic components to build the shape and heat it to be more stable.

INITIAL GENERATIVE DESIGN [SIMULATION OUTCOME] Baed on the algorithm showed before, we can generate the shape. Then we utilize the simple and basic components to build the shape and heat it to be more stable.

INITIAL PROPOSAL [ PROPOSAL]

[ AUGMENTATION REALITY ]

· · · · · ·

Hologram Interface Assembling Test Re-assemble Tracking System Computer Thinking

AUGMENTATION [ HOLOGRAMS ] We utilize the HoloLens to achieve the augmented reality. We design the interface to guide the fabrication and do the interaction between the human and computer. Computer thinking is applied into our design to generate the design based on the physical model.

Augmented Reality

Interface

AUGMENTATION [ WORK FLOW ]

Assembling Build under the guidance of HoloLens

Re-assembling Change the position of components one by one under the direction of HoloLens

Different Requirement Users no longer need this product and have other needs

Production Different size of components

Packing Different products require different number of components

Select Product According to the number of purchased products, choose different product designs

Scan and calculate Identify the number of different size components in the existing object

Shipping Shipping

AUGMENTATION [ INTERFACE FOR HOLOLENS ]

AUGMENTATION [ ASSEMBLIE TEST ] Under the guide of he HoloLens, we start the first attempt. We utilize the system to generate the chair and build it with the AR technology.

The process of fabrication

AUGMENTATION [ ASSEMBLIE TEST ] Under the guide of he HoloLens, we try to apply this to make complex model and develp into architecture scal.

The process of fabrication

AUGMENTATION [ RE-ASSEMBLE ] In this project, the component is utilized to assemble the object. Thereforem it could be re-used. The system is flexible. The computer could distinguish the main structure which would be remained. We could change the design all the time to re-assemble into other objects according to the users' requirments.

The concept of re-assemble

The process of re-assemble

AUGMENTATION [ WORK FLOW ]

Scene

Interface

The relationship among the human, computer and kinect

Fabrication with the HoloLens

Change the design in the process of fabrication

The digital model in the real world

Put the digital model in the scene

Change the design in the process of fabrication

Computer re-generate the design according to the physical change

Finial work

AUGMENTED REALITY [ TRACKING SYSTEM ] We utilize the kinect to track the component. There are two kinect to establish the 3D digital world in real time. Kinect could build the point cloud according to scan the physical model. Then, the algorithm could translate the point into surfaces and finially build the box which is reprensting the component.

Tracking system

Scence

Kinect scan the scene

Point cloud

Scan the componet

Generate the points

Distinguish the colour

Select the component colour

Build the 3D point cloud

Build the box

Scan the component

Scan the rotation

Scan the scale

Scan the movement

AUGMENTED REALITY [ COMPUTER THINKING ] Here is the library of the computer thinking for phydical model.

AUGMENTED REALITY [ COMPUTER TRAINING ] Before applying the computer thinking, we need to train the computer of the connections of the components. We explain the generative logic above. We input all the possibilities of the connections in to computer. Therefore, when the system recognize the different between the design and physical fabrication, the computer will generate a new design based on the change which is made by users.

AUGMENTED REALITY [ COMPUTER THINKING ]

Original fabrication

Original design

Change the design during the fabrication

Original outcome

Final work after computer thinking

Computer thingking process

AUGMENTED REALITY [ WORK FLOW ] Baed on the algorithm showed before, we can generate the shape. Then we utilize the simple and basic components to build the shape and heat it to be more stable. Baed on the algorithm showed before, we can generate the shape. Then we utilize the simple and basic components to build the shape and heat it to be more stable.

Two kinects scan the space in 3D

Scan the physical model

Assembling the model according to the guide

Changing the design during the fabrication

Computer re-generate new model

Re-generate again.

Changing the design during the fabrication

New model

[ ARCHITECTURE DESIGN ]

· Site Analysis · Architectural Proposal

ARCHITECTURE DESIGN [ SITE ANALYSIS]

The site is located in a high-density city in Zhejiang Province.The site is an old district and is surrounded by high-density building.There are a lot of trees around the site, which can be used for construction.

ARCHITECTURE DESIGN [ ARCHITECTURE PROPOSAL] The function of the building is the entertainment and leisure place for the residents of the town. It is divided into many small spaces for residents to carry out different activities, such as drinking tea, playing chess and so on. The building could be reassembled when there is a major event in the town. Rebuilding into a small theater with a large space can accommodate more viewers at the same time.

ARCHITECTURE DESIGN [ ARCHITECTURE ELEMENTS]

Column

Staircase

Wall