Bartlett BPro RC9 2018/19_DIFfusion by SoomeenHahm Design

DIF•fusion

DIF•fusion MARCH ARCHITECTURAL DESIGN 2018-19 THE BARTLETT SCHOOL OF ARCHITECTURE | UCL

RC9 2018-19

Research Cluster 9

TUTOR SOOMEEN HAHM, ALVARO LOPEZ RODRIGUEZ MEMBER TENG WANG, MINZHE SONG, DANPING MENG, ROUXI LYU, SIWEI QIN

DIFâ&#x20AC;¢fusion

Augmented assembly of metal curved structure TUTOR SOOMEEN HAHM ALVARO LOPEZ RODRIGUEZ MEMBER TENG WANG MINZHE SONG DANPING MENG ROUXI LYU SIWEI QIN

ABSTRACT In this project, we suggest to craft metal structure in a brand-new way to achieve contemporary aesthetics that has the richness and exuberance that we can find from traditional ironwork. We propose to do so by generating complex but highly controlled forms using agent-based algorithm and execute the resulting digital model using Augmented Reality technology. In this way, although the fabrication process fully relies on human hands, but the richness of the overall structure is coming from sophisticated digital calculations. The complexity of the project is established using agent-based algorithms to generate highly controlled sets of forms. The proposal uses a digital tool set is specifically developed based on the combination of Boids Algorithm (â&#x20AC;&#x153;Boidsâ&#x20AC;? n.d.) and Topological Optimization analysis. The resulting geometries becomes base guidelines for the physical output. However, as the resulting geometries are spacial curves, another step of digital optimization process were introduced in consideration of the physical constraints such as limitation of material size etc . At the end, the curves are categorized into two types of components: entwined joinery and individual curve segments. Entwined joinery was a rational choice for this project. This technique uses material friction with no requirements of heavy-duty tools or high-tech digital skills such as welding or robotic bending. Additionally, joints are produced with the assistance of bespoke designed toolbox to provide higher control and power assistance for human makers. On the other hand, the second type of components - individual curve segments are made using commercial workshop tools.

CONTENTS Initial Works

01 Initial Attemps

High Resolution Design Crochet Boids

02 Initial Studies

Algorithm Attempts Column Design Tests Physical Model Test

Current Works

03 Project Introducion Reference Augmented Reality

04 Material Study Metal Feature Machine Learning Pattern Making Joint Making Material Tests

05 Algorithm Development Flocking Simulation Initial Design Tests Algorithm Optimization

06 Design Exploration

Design Language Chair Study Column Study Bridge Design BPro Show

07 Fabrication Process Combination Method Tool Design

08 Augmented Reality Initial Test Interface Development AR Fabrication

09 Future Proposal

BPro Show Workflow Architecture Proposal

Initial Attempts _ High Resolution Design _ Crochet _ Boids

The initial study is more about material and digital test. We did three different researches. One is about how to use weave and crochet logic to make a structure like pavillion. We also tried use metal bar or metal pipe to simulate linear system. In additon, some of us focused on high resolution design. This design workshop inspired us a lot for our following studies.

| High Resolution Design |

High Resolution Design is inspired by some projects which made by components, using certain algorithm to control the parameters of the model in order to design defferent shape of components, then combine them together.

fig. 11

fig. 9

fig. 12

fig. 10

fig. 13

fig. 9 & 10 & 11 & 12 & 13: The response to this provocation is a swarm of components that wrap, filter, and divide space to create a series of different teaching areas. This swarm is fabricated from EPS foam blocks that are carved with a hotwire by an industrial robot.

DIFâ&#x20AC;¢fusion | INITIAL ATTEMPTS

/patterns

/ wall high density small / many

/ column low density small / many

/ column high density small / many

DIFâ&#x20AC;¢fusion | INITIAL ATTEMPTS

/ column low density large / few

/ platform high density small / many

| Crochet | Different ropes have different characteristics that affect the weaving effect. The following six materials were selected for the weaving experiment. Some of their characteristics were compared, including diameter, price, friction and degree of deformation.

/ compare

Name

Diameter

Price

Vinyl tube

Silicone rubber tube

Foam

Flexible Corrugated Bellow Conduit Tube

6mm

8mm

13mm

£0.85/ per meter

£1.58/ per meter

£1.50/ per meter

£0.76/ per meter

Strength + :

Weakness - :

Strength + :

Friction

Deformation

high strength; highsupportability;

Weakness - :

severe deformation; high friction; hin diameter.

expensive; high friction; absorbs ash easily; difficult to clean.

expensive; extrusion deformation.

small friction; easy to bend; not easy deformed; cheap; lightweight.

DIFâ&#x20AC;˘fusion | INITIAL ATTEMPTS

Due to the limited length of the pipe, the connection between the pipes should be considered during the weaving process, and the method does not affect the appearance and can be well connected.

/ connection method

tape

heat

| Crochet |

A craft of hand knitting known as crochet is referred to. A physical model is made by repeating this technique. The interesting thing is that by controlling how many rings are involved in each layer of ditches, the size of the next circle will change. So this production can take on a form of natural growth, even without human control.

/ cross weaving

/ mixed weaving

/ increase

If the object finally wants to present an enlarged shape, then the length of the next layer needs to be greater than the length of the previous layer, so that the number of holes should be increased to achieve this effect.

DIFâ&#x20AC;˘fusion | INITIAL ATTEMPTS

/ knitting weaving

/ short needle weaving

/ decrease

Similarly, if the object wants to assume a gradually shrinking shape, it needs to be the length of the next layer is smaller than the length of the upper layer, so the number of holes should be reduced to achieve this effect.

| Crochet |

A new dome image is formed by the combination of dome and hyperbola. In the process, the dome is woven from the bottom to the top, and the nodes are continuously reduced to form a dome. Finally, the hyperbola part is increasing the nodes number.

/ physical model

front view

left view

DIFâ&#x20AC;¢fusion | INITIAL ATTEMPTS

back view

external view

right view

external view

internal view

| Boids|

As with most artificial life simulations, Boids is an example of emergent behavior; that is, the complexity of Boids arises from the interaction of individual agents (the boids, in this case) adhering to a set of simple rules.

/ basic logic_boids

DIFâ&#x20AC;¢fusion | INITIAL ATTEMPTS

/ basic logic_polyline

| Boids | The agent of this project is finding shortest way. Firstly, put amount of points on the space. Then, drawing the curve to ensure the possible route of design. Moreover, find the shortest way between the near point in a centain length. Finally, connecting them with polylines.

/ logic of generation

/ patterns

DIFâ&#x20AC;¢fusion | INITIAL ATTEMPTS

/ aggregation

Initial Studies _ Algorithm Attempts

_ Column Design Tests _ Physical Model Test

After doing material tests, we tried a lot of algorithms which can be used in linear system. We used shortest path, perlin noise and following path, finally we found flocking simulation system is appropriate for our project. Next, we did a lot of studies on this algorithm and tried to make furnitures or structures to test the design language, then we would make some small scale of physical models to experiment if we can really make it, if not, we will keep fixing the algorithm. Above all, we kept designing and changing among algorithm development, digital model tests and physical model tests.

| Algorithm Attempts |

Shortest Paths The first algorithm which we tried is that, basically, deforming the given geometry into spatial points and then to find the shortest path in some randomly selective points and forming the special line by these method. After pipes forming the functional space could be defined.

/ basic logic

Suppose this is a specific room;

Randomly take a corner and evenly arrange points in the physical building;

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

These points are connected one by one;

Make these tubes grow on the previous lines.

| Algorithm Attempts | Shortest Paths The shortest path algorithm generates some random points in a box, and determines two other points as the starting point, then connects them with other random points to calculate the shortest path. The following two pictures are two structures made in this way, walls and pavilions.

/ basic logic development

create a box

start points connect with 3D random points

create a set of random points in box

use shortest walk arithmetic create shortest way between two points and random points

create two points as start points for shortest walk

curces turn into pipes.

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

| Algorithm Attempts |

Shortest Paths This logic can form a space as we presupposed. However, we find out that it could be better if the logic of pipe generate with its own logic instead of setting the specific geometry at the beginning.

/ step one

/ step two

/ step three

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

/ step four

/ step five

/ step six

| Algorithm Attempts | As the result, the improved algorithm used some formula to make some selection of direction, length and so on when the pipes grow. After that we thought the logic could be more complicated to form an more interesting and attractive space with a more persuasive logic.

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

| Algorithm Attempts | Pipes of different thickness can have different practical functions. In detail, the thickest pipe can bear the weight; the medium pipe can be decorated; and the thinnest pipe can be used as a node. Thus we studied how pipes of different thicknesses should be combined to form an inheritance system.

/ water pipe patterns

/ electricity pipe patterns

Type 1

Only electricity pipe

Type 2

Water pipe + electricity pipe

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

/ joint+supporting

| Algorithm Attempts |

Following Paths The task is to traverse the path in a given direction (entering on the left, exiting on the right) while keeping its center on the grey region. in the case the path defined in a serious connected lines (polyline) and a radius. This behavior is related to containment and wall following but differs because the path implies a direction of travel. A non-zero path radius produces a sort of "sloppy path following". That is, the path following goal is considered to be met as long as the vehicle is within a certain neighborhood of the path spine. The path following requirement can be made more strict by reducing the radius toward zero.

/ basic logic

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

/ chair formation

| Algorithm Attempts |

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

| Algorithm Attempts |

Perlin Noise Perlin Noise is an algorithm that can imitate natural forms. It grows randomly under certain parameters and can form various organic and natural forms. The algorithm extract the main control lines that can represent the overall form from the lines generated by Perlin Noise, and change the fluctuation of the lines, then generate transition lines between the control lines, so as to grow various forms as shown in the following figure.

/ basic logic

Select a part of perlin noise

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

Extract main control lines

Generate shape

| Column Design Tests |

Using metal steel and plastic pipe as the main physical material. The steel is strong and stable enough to be the structure. As well as the rubber pipe could wrap the metal steel to enrich the design language.

/ material type

Steel

Pipe

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

/ combination

| Column Design Tests |

Pipe and Metal Additionally, rubber pipe has high tolerance of the metal curve. if the metal is not smoothly curved enough, rubber pipe can effectively hide this.

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

| Column Design Tests |

Pipe Patterns To crochet, different amount of pipe used will get to different weave method. Besides, these variety of knit texture are also a part of the design language.

/ pipe number

two pipes

four pipes

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

one pipe

three pipes

| Column Design Tests |

Model Hierarchy Here are the process of adding different thickness of metal steel and plastic pipe to the model. It shows that the visual effect can be influenced by both material and thickness.

/ system

metal

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

plastic pipe

| Column Design Tests |

Component Here are four patterns we designed follow two agent system, and separate to different part like whole metal steel, metal steel all rounded by plastic pipe, metal steel with part pipe.

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

| Physical Model Test |

Physical Model For the physical model, utilizing argumented reality is great help to scan the design in the real world in advance. Also, it could improve the quality and speed of constructors to make it. Besides, constructors could have a quick look to compare the finished model with the design.

DIFâ&#x20AC;˘fusion | INITIAL STUDIES

trying to simulate the metal curves into the visual image we see in HoloLens.

there still exists some problem with the precision between visual and reality.

| Physical Model Test |

Physical Model These photos displays the condition of using Hololens to make models and compare the finished model with design.

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

| Physical Model Test |

Physical Model These photos displays the condition of using Hololens to make models and compare the finished model with design.

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

| Physical Model Test |

Physical Model These photos displays the details of ruber pipe and metal curves.

DIFâ&#x20AC;¢fusion | INITIAL STUDIES

Project Introduction _ Reference

_ Augmented Reality In this project, we suggest to craft metal structure in a brand-new way to achieve contemporary aesthetics that has the richness and experience that we can find from traditional ironwork. We propose to do so by generating complex but highly controlled forms using agent-based algorithm and execute the resulting digital model using Augmented Reality technology. In this way, although the fabrication process fully relies on human hands, but the richness of the overall structure is coming from sophisticated digital calculations.

| References |

In this project, we suggest to craft metal structure in a brand-new way to achieve contemporary aesthetics that has the richness and exuberance that we can find from traditional ironwork.

fig. 1

fig. 1: Gate cresting (left) & Chancel screen (right) from 16 century-iron-work ("Gate Cresting | V&A Search the Collection! 2019) fig. 2: Automatic Robot Bending Tubing. http:// www.youtube.com/watch?v=PvPNHbWXnwE

fig. 2

DIFâ&#x20AC;¢fusion | PROJECT INTRODUCTION

fig. 3

fig. 4

fig. 3 & 4: "MX3D Bridge." 2018. Joris Laarman. October 2018. http://www.jorislaarman.com/ work/mx3d-brdge/. fig. 5: MX3D Bridge update project update

fig. 5

| Augmented Reality |

Building System With Mixed Reality The biggest difficulty in architectural design is to bring the content on the screen to the actual, and hololens can make the virtual design into the actual model, and then observe its dimensions, proportions, modeling and other aspects. Microsoftâ&#x20AC;&#x2122;s hololens allows designers to see holographic images and real-time feedback mixed with reality, which is completely different from our previous design.

fig. 6: HENN Pop-up Factory. http://vimeo. com/287214471

fig. 6

DIFâ&#x20AC;¢fusion | PROJECT INTRODUCTION

fig. 7

fig. 8

fig. 7 & 8: Augmented Robotics: RobArch 2018 Workshop. http://vimeo.com/290215560

| Challenge | In our project, we mainly challenged three aspects of metal work. The first one is to use Augmented Reality Technology to aid our assembly and making process. Then, we designed a tool specially for twisting components, it is better work with furnace compared with traditional metal making method. Moreover, our joint system is more flexible and high efficiency.

(×) Complexity: Difficult Duration: Long Precision: Low Technicality: Low

(×) Form: Cold Complexity: Difficult Manufacturing duration: Long Precision: Low Aesthetics: Low Results of types: less

(×) Complexity: Difficult Manufacturing duration: Long Assembly duration: Long Precision: Low Technicality: Low Stability: High Aesthetics: Low

DIF•fusion | PROJECT INTRODUCTION

(✓) Complexity: Easy Duration: Short Precision: High Technicality: High

(✓) Form: Hot Complexity: Difficult Manufacturing duration: Short Precision: High Aesthetics: High Results of types: more

(✓) Complexity: Easy Manufacturing duration: Short Assembly duration: Short Precision: High Technicality: High Stability: High Aesthetics: High

| Argumented Reality |

DIFâ&#x20AC;¢fusion | PROJECT INTRODUCTION

| Work Flow | The basic workflow will be firstly select approprite material which is iron we selected, then do experiments as much as possible so as to fully understand the character of metal. Then we do the algorithm study and patterns design toghther, they impact each other. The joint and tool design is to help realize the physical model which made by certain algorithm. Next is the fabrication part.

Algorithm Development

Material

Material Test

Design Language

DIFâ&#x20AC;¢fusion | PROJECT INTRODUCTION

Joint Design

Design Process

Fabrication

Future Proposal

Tool Design

Material Research _ Metal Feature

_ Machine Learning _ Pattern Making _ Joint Making

_ Material Tests Steel was chosen as the main material in our project. Steel has been widely used in architecture structures due to its high strength, but we wanted to use iron to create new design languages. To realise that, some unusual method are used to process it such as bending, weaving and twisting. So that the cold material can form warm shapes.

| Metal Feature | There are many kinds of metal. Steel is the main material we chose. Also, iron and aluminum are used in some test and concept model. Steel is an alloy of iron and carbon, and sometimes other elements. Because of its high tensile strength and low cost, it is a major component used in buildings, infrastructure, tools, ships, automobiles, machines, appliances, and weapons.

book<Material ConneXion> George M. Beylerain andrew dent Edited by Anita Moryadas

DIF•fusion | MATERIAL RESEARCH

Steel are metal alloys based on iron and carbon. The carbon content (which does not exceed 2%) determines their properties, in the same way that the addition (one then speaks of alloyed steels) of other components can modify their properties, allowing special and /or non-oxidizing steels to be obtained. Density: about 7,850kg/m2 Melting point: about 1,500℃

/ strength + :

/ weakness - :

can be recycled； mechancial strength； malleability； elasticity； impact resistance; hardness.

weight; corrosion.

| Metal Feature | At the beginning of the material testing period, we chose solid metal stick, metal tube, square stick and square tube as the main research metarial, and then carried out various tests on them. The test at this stage is without rules, in order to fully understand the materials and select the most suitable ones of our project.

fig.1

fig.1: Gate cresting (left) & Chancel screen (right) from 16th century - ironwork (â&#x20AC;&#x153;Gate Cresting | V&A Search the Collectionsâ&#x20AC;? 2019)

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

| Metal Feature | In the process of research and production of the physical models, we found that the twist pattern is very fancy and has a special texture. These textures are made by heating metal and then twist and retwist them. These three prototypes are the inspiration and foundation of our project, and the following design work is related to these design languages.

DIFâ&#x20AC;˘fusion | MATERIAL RESEARCH

prototype 1: using solid square stick to twist into this kind of texture.

prototype 2: using solid metal bar to twist. can twist 2-6 pieces of bar.

prototype 3: similar with the second prototype, but do a re-twist base on it.

| Metal Feature | We tried different radius of metal tubes and solid metal sticks for twist. Some of these prototypes were successful, but some were not very stable and could not be as expected, then we did thickness test to choose suitable thickness.

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

| Machine Learning | There are four ways to bend steel. They are three kinds of machine and manual bending separately. They can bend the steel into different degrees and radius, and suitable for different thickness. Steel can be bent into certain curve by these method. Steel is an alloy of iron and carbon, and sometimes other elements. Because of its high tensile strength and low cost, it is a major component used in buildings, infrastructure, tools, ships, automobiles, machines, appliances, and weapons.

/ bending machine 1

/ bending machine 2

Strength + :

Weakness - :

multiple works;

small radius; thin pipe or solid.

automatic; radius changable; only thick pipe.

DIFâ&#x20AC;˘fusion | MATERIAL RESEARCH

/ bending machine 3

/ bending machine 4

Strength + :

Weakness - :

bigger radius;

can not change radius.

easy making;

not precise.

| Machine Learning | Heating is a powerful working method. After heating, metal can be easily changed into any shapes as we want. If the fire is big enough, we even can twist thick steel, which enriched our design language. Three different degrees of fire was tested, they can deal with different thickness of steel.

/ torch

Strength + : high intensity;

Weakness - : waste gas; only thin bar; waste time.

/ heating gun

Strength + :

high intensity;

Weakness - :

waste gas; waste time.

DIF•fusion | MATERIAL RESEARCH

/ burning

/ hand twist

Strength + :

Weakness - :

high intensity；

waste time.

easy making;

not stable.

| Machine Learning | Metals have many subclassification according to different standard. Since they have different characteristic, they can only processed by certain method. Metals have many subclassification according to different standard. Since they have different characteristic, they can only processed by certain method.

/ bend_Polyline

Solid bar Type Pipe

Round Shape Square

<6mm Radius

6-10mm >10mm

/ bend_Chamfer

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

/ bend_Curve

/ bend_Free curve

/ torch

/ heating gun

/ furnace

/ fire

/ bend_Polyline

Solid bar Type Pipe

Round Shape Square

<6mm Radius

6-10mm >10mm

/ bend_Chamfer

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

/ bend_Curve

/ bend_Free curve

/ torch

/ heating gun

/ stove

/ manual twist

| Pattern Making | The pictures below shows the process of pattern test. The pipes are cut, bent, polished welded and connected to form a shape of three branch.

/ prepare

/ cut

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

/ bend

/ combine

| Pattern Making | These are four different design to test what pattern can metal bars form with bending technique. They used different design languages and joints, but they all used logic of bending. It indicates bending is a potential method can cooperate well with different design logic.

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

| Joint Making |

Interlock This method is interlock. The idea came from the crochet model made in the first term, and following this pattern to design it.

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

| Joint Making |

Pipes Joints When two or more pipes from different systems needs to be combined parallel or vertical, this method is useful. This connection method is quite flexible to connect pipes in different directions or even connect pipes in diferent diameters. The shape, length and thickness of connection could be adapted and changed to satisfy more needs.

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

| Joint Making |

Nails When two or more pipes from different systems are combined in parallel without gaps, they will form a surface, There are many ways to connect them by different joints as shown below.

/ type A

/ type B

Slotting in the steel, and use screw to connect them across the hole in steel. It is the easiest method.

Using metal module to fix steel together. It avoid destroying the steel but it seems obviously.

/ type C

/ type D

3D printing with rubber. It is small and also avoid detroying the steel, but it is expensive.

Using metal module to fix steel together. It is the firmest method.

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

100

| Joint Making |

End to End Connection When we design pipes in the same system, very long pipes with many turns are needed. It is hard to transport and process, so end to end joint is useful. The length of pipe can be extended by this method, so we can manage a more complex system by these connections.

component

101

cut

polish

bend

DIFâ&#x20AC;˘fusion | MATERIAL RESEARCH

This method is about cross hitch, which mainly use soft material to connect metal bars, but this basically is useful to connect two vertical pipes.

102

| Material Tests | Pipe Rebound Test When using bending machine, the degree is uncertain, which may cause many errors in assemblage. It can be measured precisely by ruler or protractor. Another thing deserve to be mentioned is steel has character of spring back. That means we have to bend a little more degree than we need.

Degree measure can be transferred to length measure. The latter can be measured precisely and calculated by the formula: L1= L2= 1/2 Î r = 1.57r

103

DIF•fusion | MATERIAL RESEARCH

/ uncertain angle

45° 46°

/ square and protractor----45 degree

/ control by length

92°

90°

/ square----90 degree

104

| Material Tests | Pipe Rebound Test We find it is difficult to get the angle of the pipe under control, because the long iron pipes very heavy and the fixed plate can not hold it at the same horizontal line during the whole process of bending.

105

DIFâ&#x20AC;˘fusion | MATERIAL RESEARCH

/ error accumulation Problem: the small errors will accumulate to big problems Solution: change our design language and bend metal into curves, which may allow more errors.

/ prone to twist at joints

/ angle control

Problem: prone to twist at joints Solution: joints can be settled by nails simply, but If remain some part unset, it be an alterable structure.

Problem: the angles are hard to control Solution: 1. Measure length by ruler or measure angle by square and protractor 2. Using augment reality technique to control the angle and position.

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| Material Tests | Twist Thickness Test Different thicknesses can be made by different methods. For example, a stick of less than 8mm can be realized by cold twist, and a thicker stick must rely on a stove, thus involving the design of the stove twist tool.

5mm

6mm

cold twist

107

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

7mm

10mm

furnace

108

place the bar above two bricks

put a heavy thing on it

same radius but twist

contrast the radius of curve

109

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

110

| Material Tests | Twist Thickness Test After doing contrast experiments between different radius of twist patterns, we found 4mm is quite weak, and the 8mm one has highest intensity which we can control it by using our designed tools.

6mm

8mm

111

DIFâ&#x20AC;¢fusion | MATERIAL RESEARCH

4mm

6mm

8mm

112

Algorithm Development _ Flocking Simulation _ Initial Design Tests

_ Algorithm Optimization Our digital model is based on algorithm, and the structure should be built according to the algorithm instead of manually. There are lots of algorithms suitable to generate liner growth. ‘Flocking’ can form complex interlaced pattern. ‘Perlin noise’ can grow into natural and organic curves. ‘Shortest path’ can generate clear polylines. Finally, the ‘Flocking’ algorithm was chosen to design our final model. Control the path of agent move can be our aim.

| Flocking Simulation | Flock behaviour is the behaviour exhinited when a group of birds, calls a flock. Computer simulations and mathematical models which have been developed to emulate the flocking behaviour of birds could generally be applied also to the "flocking" behaviour of other species.

desired desired

/ separation

115

/ alignment

/ cohesion

DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

116

| Flocking Simulation | 2D Patterns There are five controlling factors of the agent. Neighbor Radius is the range of agent, which be affected by the control points. Separate is the power of repulsion. Align is used to control the moving route of each point in the same agent. Separate distance is the distance between each point. Cohesion is used to keep the single point to be gathered or separated.

repeller point attractor point

117

DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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| Flocking Simulation | 2D Patterns Flock behaviour is the behaviour exhinited when a group of birds, calls a flock. Computer simulations and mathematical models which have been developed to emulate the flocking behaviour of birds could generally be applied also to the "flocking" behaviour of other species.

repeller point attractor point

119

DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

120

repeller point attractor point

121

DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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repeller point attractor point

123

DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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| Flocking Simulation | 3D Patterns When the repeller is set, the agents will avoid this point, and the trajectory formed here will diverge more than elsewhere.

/ repeller

repeller point attractor point

125

DIFâ&#x20AC;˘fusion | ALGORITHM DEVELOPMENT

Similarly, when the attractor is set, the agents tends to move towards this point, and the trajectory formed here will converge more than elsewhere.

/ attractor

126

| Flocking Simulation | 3D Patterns For 3D pattern, some control points are set up. Adjusting the power of attraction and repulsion, movement of the agents will be influenced. It could be controlled to meet our requirement.Â

/ combine

repeller point attractor point

127

DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

128

| Flocking Simulation | Chair Generation This logic can generate not only structures like pillars, but also furniture like chairs. The pictures below shows how to control the attraction and repulsion points to generate the chair

repeller point attractor point

129

DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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| Flocking Simulation | Arch Generation Also, larger scale structure, even architectural scale structure such as bridge or breakout space can be generated if we add more control points.

repeller point attractor point

131

DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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| Initial Design Tests | The following figure shows some digital model designs at the scale of furniture. It can be seen how the attraction point and the repulsion point control the furniture form.

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| Initial Design Tests | The following figure shows some digital model designs at the scale of architecture. They are pavilion and bridge controlled by attractor and repeller.

135

DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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| Initial Design Tests | The following figure shows some digital model designs at the scale of architecture. They are pavilion and bridge controlled by attractor and repeller.

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DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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| Algorithm Optimization | After trying to design some prototypes, we found it is difficult to combine all the elements together and make them stable, so we optimize the algorithm so as to have another layer to joint them together.

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DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

/improve all elements stable

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| Algorithm Optimization | The following diagrams show that where and how to add truss between every two components, and how to generate twist pattern so as to suit different situation in models.

generate curves

seperate curves (curvature = 0)

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DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

add trusses

combine with joints

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DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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DIFâ&#x20AC;¢fusion | ALGORITHM DEVELOPMENT

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Design Exploration _ Design Language _ Chair Study

_ Column Study

_ Bridge Design Bpro Show This part displays the process of making design language. It could be separated to two parts. One is material language, which means the different proportion of using different material and the different thickness of the pipe could make variety effects. The other is pattern language, which means the various way of dealing with the basic component, such as crochet, weaving and twisting are also a entertaining way to enrich the design.

| Design Language | Weave Using weave as a design language of the joint. Two sticks are the basic structure could be weaved. As the increase of sticks, the weaving pattern could have more directions.

/ stick number

Two sticks

Three sticks

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DIFâ&#x20AC;¢fusion | Design Exploration

Four sticks

Five sticks

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| Design Language | Weave Here are the physical model we did to test how the weaving metal steels will be. And the right part is the whole digital model of design, it could be seen that the weaving joint looks strange on polyline.

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DIFâ&#x20AC;¢fusion | Design Exploration

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| Design Language | Twist

Twisting is the most attractive part of the design language. It is a challenge to twist strong metal steel without heating. Moreover when the power and frequency of twisting are changed, it could show different results. When twisting reverse, it will produce a space inside the model.

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| Design Language | Twist Here are the physical model to test the effect of using twisting part as the joint.

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DIFâ&#x20AC;¢fusion | Design Exploration

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| Design Language |

To compare two different design language twist and weave, we consider them with six aspects, then choose twist as our main design language.

Time

Price

Corner

Twist ( â&#x153;&#x201C; )

15 min

Medium

Curve

Weave ( Ă&#x2014; )

30 min

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Low

Right angle

DIFâ&#x20AC;˘fusion | Design Exploration

Demand for AR

Processing method

Gas consumption

High

Furnace

High

Low

Torch

Medium

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| Design Language | Twisting is the most attractive part of the design language. It is a challenge to twist strong metal steel without heating. Moreover when the power and frequency of twisting are changed, it could show different results. When twisting reverse, it will produce a space inside the model.

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DIFâ&#x20AC;¢fusion | Design Exploration

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DIFâ&#x20AC;¢fusion | Design Exploration

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DIFâ&#x20AC;¢fusion | Design Exploration

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| Chair Study | Digital Model Design Next part we considered function and structure of design, as a practiceďź&#x152;we designed a lot of chiarďź&#x152;and some of them are similar but with little adjustment in certain parameter. In this way, we can create some prototype of chair and try to choose one and really make it.

Agent number: 8 Neighbour radius: 200 Alien:500 Separate:100

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Agent number: 8 Neighbour radius:200 Alien:1800 Separate:100

DIFâ&#x20AC;˘fusion | Design Exploration

Agent number: 11 Neighbour radius:100 Alien:1800 Separate:70

Agent number: 9 Neighbour radius:200 Alien:1800 Separate:100

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| Chair Study | Components of Chair We chose a chiar and wanted to make real model of it so as to test our joint system and algorithm. About this chair, we separate it into four parts, the main structure are sitting area and two bottom parts, and truss system is for joint all parts and make it become a whole

T system

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A System

B System

DIFâ&#x20AC;˘fusion | Design Exploration

C System

Chair design proposal 172

| Chair Study | In the original prototype production process, we used HoloLens to help us bend the curve into a specific 3-dimension shape and determine the direction of the twist branches. And then we assemble every components together.

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DIFâ&#x20AC;¢fusion | Design Exploration

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| Chair Study | Model in Progress

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| Column Study | Physical Model

After making the chair, we found some problem like the density of the chair is too high, and there has some useless elements which we can actually remove them. In this way, we want to make another model to try to use less material but create elegant model.

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DIFâ&#x20AC;¢fusion | Design Exploration

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| Column Study | Physical Model Details

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DIFâ&#x20AC;¢fusion | Design Exploration

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| Bridge Design BPro Show |

Growth Process

/ one surface grow in one box

/ original curve

/ seperate pipe

/ add truss

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DIFâ&#x20AC;¢fusion | DESIGN EXPLORATION

/ add joint 188

| Bridge Design BPro Show | This bridge are made by 6 forms of flocking simulation, two components are twisting joint and curve pipe.

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DIFâ&#x20AC;¢fusion | DESIGN EXPLORATION

/ two types of component

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DIFâ&#x20AC;¢fusion | DESIGN EXPLORATION

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Fabrication Process _ Combination Method _ Tool Design

In this part, the whole fabrication process could be seen. AR glasses with Hololens is a beneficial tools to see the completion effect in the real world. And it is contribute to improve the degree of accuracy in making physical models as it could be easily compared with the digital model in Hololens at any time.

| Combination Method |

Twist Development As we have learned from previous experience, the metal stick to twist directly is not a way of make sence, thus, we improved the joint method by combining the metal stick with the metal tube together, which makes the assembly process more flexible.

developement

/ solid metal stick 195

DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

/ solid metal stick + metal tube 196

| Combination Method |

Twist Comparsion

branches system

/ joint

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DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

/ joint with pipe

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| Combination Method |

Twist Pattern As we have learned from previous experience, the metal stick to twist directly is not a way of make sence, thus, we improved the joint method by combining the metal stick with the metal tube together, which makes the assembly process more flexible.

/ type one

2 ends

/ type two

2 ends

1 end

3 ends

1 end

4 ends

1 end

2 ends

199

DIFâ&#x20AC;˘fusion | FABRICATION PROCESS

/ type three

4 ends

2 branches

3 ends

2 branches

4 ends

2 branches

4 ends

2 branches

3 branches

1 branch

3 branches

2 branches

4 ends

2 branches

4 ends

1 branches

4 ends

3 branches

200

| Combination Method |

Twist Comparsion

2 ends

201

1 end 4 ends

4 ends

DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

4 ends 1 branch

4 ends 4 ends 2 branches 1 branch

4 ends 3 branches

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| Joint Making |

Twist Model Details

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DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

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| Combination Method |

Twisting Part and Bending Part In order to make the twist part and the end part better connected, we tried a lot of ways to choose a time-saving, labor-saving, and firm connection. We baslcally chose metal glue from five ways, such as spot weliding, welding, screw, super glue and metal glue, thinking that it is more in line with our concept.

ďź&#x2C6;Ă&#x2014;ďź&#x2030; load bearing: 28++ appearance: abvious time-consuming: 1min

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DIF•fusion | FABRICATION PROCESS

（×） load bearing: 36++ appearance: hidden time-consuming: 5min

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| Combination Method |

ďź&#x2C6;Ă&#x2014;ďź&#x2030; load bearing: 21++ appearance: abvious time-consuming: 5min

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DIF•fusion | FABRICATION PROCESS

（×） load bearing: 23++ appearance: hidden time-consuming: 1min

（✓） load bearing: 30++ appearance: hidden time-consuming: 1min

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| Combination Method |

（×） load bearing: 23++ appearance: hidden time-consuming: 1min

（✓） load bearing: 30++ appearance: hidden time-consuming: 1min

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DIF•fusion | FABRICATION PROCESS

（×） load bearing: 36++ appearance: hidden time-consuming: 5min

（×） load bearing: 28++ appearance: abvious time-consuming: 1min

（×） load bearing: 21++ appearance: abvious time-consuming: 5min

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| Tool Design |

Twist Tool 1.0 Diging a hole in a metal panel, then using a long arm to twist pipes. We could teist max 6 metal sticks at the same time.

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DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

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| Tool Design |

Twist Tool 2.0 To solve the problem in the last bending tool, it could be improved to be fabricated, so that the handles could be avoid from the obstacles flexibly.

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DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

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| Tool Design |

Twist Tool 3.0 After heating, metal sticks will be soft enough to be adjusted.Thus, we could turn the bar on tureplate to twist thicker sticks.

using the pressure of screws to fasten metal sticks.

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DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

/ process of twisting

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| Tool Design |

Twist Tool 3.0 After heating, metal sticks will be soft enough to be adjusted.Thus, we could turn the bar on tureplate to twist thicker sticks.

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DIFâ&#x20AC;˘fusion | FABRICATION PROCESS

/ Using condition

/ Problem

/ Solusion

Twisting Bar need to be longer and portable to help user save power.

Needing to add a structure to hold the stell and control the bending angle.

Because welding is not stable enough to support the power of bending, so we change the design of fixator

When we twiting it, the supporting bar inclineto one side, so we could add more supporting part to make it more strong.

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| Tool Design |

Twist Tool Development There are five kinds of twisting tools we design and made for making the physical model, and as our experience of using them, we found their shortages and advantages, here is the analyse of these twisting tools.

/ for thin sticks

/ changable arms

/ limiting length

Size: ++

Size: +

Veracity: +++

Veracity: ++

Convenience: ++

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Convenience: +++

Convenience: ++

DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

/ for thick sticks

/ for thick sticks 2.0

Size: +++

Veracity: ++

Veracity: +++

Convenience: ++

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| Tool Design |

/wood panel with holes

221

/add cube to uplift

/another wood panel with holes

DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

/insert sticks into holes

/add metal elements / hold model in a certain position

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| Tool Design |

the connection part can be rotated to any angle.

there are several holes on the panel and people can select hole to insert stick according to models.

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DIFâ&#x20AC;˘fusion | FABRICATION PROCESS

we can adjust the position of sticks which means which hole to insert and adjust the height of connecting part and the angle of connecting part to suit all kinds of models.

224

| Tool Design |

Frame Design In order to efficiently help people with assembly process, we designed a frame to hold model in a certain position, in this way, people can match real model with HoloLens images. This frame are made by wood panel and wood sticks. we can adjust the position of sticks which means which hole to insert and adjust the height of connecting part and the angle of connecting part to suit all kinds of models.

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DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

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| Tool Design |

Frame Design In order to make it easy for us to assemble physical models, making a suitable frame can not only effectively improve our construction efficiency, but also improve the accuracy of assembly, and better match the model in virtual reality. There are real frames and some details.

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DIFâ&#x20AC;¢fusion | FABRICATION PROCESS

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Augmented Reality _ Initial Test

_ Interface Development _ AR Fabrication

The method of the production was straightforward: Firstly, we used our algorithmic tool to generate desired form. Secondly, we produced entwined joints and curved segments through AR. Finally, the entire structure was assembled together again through AR. There was no involvement of high-tech robots or heavy-duty machines. As the entwining and assembly processes are largely based on weaving motion, it is nearly impossible to produce the same using any robotic processes.

| Augmented Fabrication | HoloLens, through the use of the HPU, uses sensual and natural interface commands. Windows can be dragged to a particular position, as well as resized. Thus, it is convenience to put the virtual image in glasses to fit the scale and position of metal bars in real world.

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DIFâ&#x20AC;¢fusion | AUGMENTED REALITY

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| Initial Tests | At first, in the stage of learning HoloLens, we tried a lot of ways to use its different functions, such as moving, zooming in and rotating these basic functions, and then we used a very simple material to manually create a model that fits the virtual image. To understand the use, advantages and disadvantages of HoloLens

/ first perspective

233

DIFâ&#x20AC;˘fusion | AUGMENTED REALITY

Next, we try to start with a simple interface, design our own panel and then connect the grasshopper to HoloLens, so that we can implement the function of clicking the button, which lays the foundation for our next research and design.

/ third perspective

234

| Initial Tests | In addition, we introduce Algorithm into HoloLens for testing, and control the shape of the line by moving the control points with fingers to control the final shape of flocking. We can also adjust the model in real time through HoloLens to make our design process more efficient. In the original prototype production process, we used HoloLens to help us bend the curve into a specific 3-dimension shape and determine the direction of the twist branches.

/ move control points

235

DIFâ&#x20AC;¢fusion | AUGMENTED REALITY

/ bend solid metal

/ bend metal tube

236

| Initial Tests | Next, we decided to use a simple model for more in-depth research. This time we first manually test with small-scale models and flexible materials, and then use a certain thickness of iron to make a real scale model. But we still met some problem such as the precision is not satisfied.

/ column assembly (small sale)

237

DIFâ&#x20AC;¢fusion | AUGMENTED REALITY

/ column assembly (real sale)

238

| Interface Development | In order to use HoloLens more efficiently, we designed interfaces which related to the project models. The functions of these panels are developed from easy to difficult, and the appearance is also changing little by little.

the first interface is quite sample, the function only contains change components.

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DIFâ&#x20AC;˘fusion | AUGMENTED REALITY

the second is designed specially for a bending machine, it also shows the infomation of the component.

240

| Interface Development | In order to use HoloLens more efficiently, we designed panels which related to the project models. The functions of these panels are developed from easy to difficult, and the appearance is also changing little by little.

this interface is similar with the second one but improve the interface of it.

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DIFâ&#x20AC;¢fusion | AUGMENTED REALITY

this interface is a series, it is more suitable with our algorithm and assembly process.

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| AR Fabrication | The final interface is a series. The main menu consists of five parts: learn, design, bending, twisting, and assembly. Each part will appear in different interfaces when clicked, and there will be different functions and information display. Interface, we can complete the entire process of physical model production more efficiently

/ main menu this function is for design. Firstly, people can create a bounding area and adjust the shape and scale.

245

DIFâ&#x20AC;˘fusion | AUGMENTED REALITY

/ attractor and repellor Put attractors and repellors inside the bounding area, people can control the number of them.

246

/ position and scale Use HoloLens to adjust the scale and position of attractors and repellors.

247

DIFâ&#x20AC;¢fusion | AUGMENTED REALITY

/ generate Finally, click start button to generate the flocking simulation agent.

248

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DIFâ&#x20AC;¢fusion | AUGMENTED REALITY

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DIFâ&#x20AC;¢fusion | AUGMENTED REALITY

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Future Proposal _ BPro Show Workflow

_ Architecture Proposal For the future proposal, the agent such as flocking simulation and following path will be developed to a mature and controllable system. So it could be generate to pavilions, bridges, and some other public space. Metal will also be the primary material of the design. However, the design of joint to connect metal bars together and the tools to bending, twisting the metal should be more clever and portable for hand making.

| BPro Show Workflow |

Metal section pattern Select metal pipes and metal bars that match the digital model

Cut metal pipe The length of the metal pipe should meet our design requirements and use for bending

Delivery Send the cut materials to the factory

Cut metal bar Cut severval sets of metal sticks of the same length for twsiting

Delivery Send the cut materials to the factory

Bridge assembly Use frames to make bridge Bridge Fabrication

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DIFâ&#x20AC;˘fusion | FUTURE PROPOSAL

Bending machine Use Hololens and bending machine together to bend the metal pipes

Bending results Use Hololens and bending machine together to bend the metal pipes

Twisting machine Use Hololens and twisting machine together to bend the metal sticks

Twisting results Use Hololens and bending machine together to bend the metal pipes

Surface assembly Use frames to continue to combine, and add trusses and joints

Combine components Combine the results of twisting and bending, form the assembly model

Frame set up Use frames to assist in the assembly of the model, making components more precise in the assembly process

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DIFâ&#x20AC;¢fusion | FUTURE PROPOSAL

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DIFâ&#x20AC;¢fusion | FUTURE PROPOSAL

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| Architecture Proposal | Function Partition As the future proposal, we designed a large scale bridge. Since we want to make a small bridege on BPro show, we think bridge is a suitable architectural function to express our design language, algorithm and physical making skills.

Bridges The deck serves as a link between three destinations

River banks River banks connected by this bridge

Rest area People could stay in this area, shading, and so on.

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DIFâ&#x20AC;¢fusion | FUTURE PROPOSAL

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