DIGITAL DESIGN + FABRICATION SM1, 2016 SLEEPING POD Cheng Chi Yau Stephanie 723265 Michelle James, Group 1
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CONTENTS 1.0 IDEATION 1.1 Object .................................................................................................. 5-7 1.2 Object & System Analysis ................................................................... 8-9 1.3 Volume ................................................................................................ 10-11 1.4 Sketch Design ..................................................................................... 12-13 2.0 DESIGN 2.1 Design Development Intro ................................................................ 15 2.2 Design Proposal V1.1-2 ..................................................................... 16-19 2.3 Precedent Research .......................................................................... 20-21 2.4 Design Proposal V2 ............................................................................ 22-23 2.5 Prototype & Testing Effects ................................................................ 24-25 3.0 FABRICATION 3.1 Introduction ........................................................................................ 27 3.2 Design Development & Fabrication - Prototype V2 ....................... 28-31 3.3 Design Development & Fabrication - Prototype V3 ....................... 32-35 3.4 Final Prototype Development & Optimisation ................................. 36-38 3.5 Final Digital Model ............................................................................. 39 3.6 Fabrication Sequence ....................................................................... 40-41 3.7 Assembly Drawings ............................................................................ 42-43 3.8 Sleeping Pod ....................................................................................... 44-47 4.0 REFLECTION ...................................................................................................... 49-51 5.0 APPENDIX ......................................................................................................... 52-55
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1.0 IDEATION 4
Cheng Chi Yau
1.1 Object
ELEVATION
Measured Drawings
SECTION
PLAN
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Measuring Method
1.1 Object
First, I took the photos of top view, elevations and bottom view of the folding umbrella when it is closed and opened. Then, I measured the dimensions of the real object with measuring tape and marked the dimension on my sketches. Lastly, I finished the measured drawings with accurate measurement. As the sizes of the umbrella varies a lot when it is fully opened and closed, I drew the plan (1:5), elevation (1:5) and perspectives (1:1 and 1:2) in different scales in order to show all the details of it.
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PLAN
Modelling Method 1. model the handle, shaft and runner with the button on plan.
Digital Model
PERSPECTIVE
2. model one rib and stretcher on the plan; project it to the top of the shaft and bend into required angles. 3. rotate and copy the bend rib and stretcher with 60 degrees using the top of the shaft as centre. 4. create one slice of the canopy on the plan; project it to the top of the shaft and bend along the ribs. 5. rotate and copy the canopy with 60 degrees with the top of shaft as centre.
ELEVATION
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1.2 Object & System Analysis
Mechanism of the umbrella
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Umbrella when fully closed (RED part of the diagram)
The digram on left page shows how one of the ribs and stretchers works when the umbrella is closed (red), half opened (blue), and fully opened (black). The other 5 pairs of ribs and stretchers have identical properties. 1. When the object is closed, the ribs and stretcher tend to form a “M� shape; all the ribs and stretcher nearly stay vertically. 2. When the runner is pushed up, the stretcher will push the rib perpendicular to it in its mid point; while the second rib in the middle will also be pushed by the stretcher at its end point. The whole rib expands away from the shaft.
Umbrella when half opened(BLUE part of the diagram)
3. When the runner is pushed up to the top notch, stretcher will push the ribs and the first two ribs form a straight line, the last rib expands to its maximum angle (25 degrees).
Umbrella when fully opened (BLACK part of the diagram)
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Sketch Model
1.3 Volume
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This design is inspired by the mechanism of folding umbrella. The vertical shafts in the grids (bone) can be shortened like the shaft of umbrella. The ribs of the pyramids form continuous W – shapes and can be compressed vertically like the ribs of umbrella. Drawing paper and tracing paper are used to cover parts of the pyramids to form the skin of the model. Volume is created within the pyramids; it varies with the height of pyramids.
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1.4 Sketch Design
Design 1 The main frame expands from the top circle; each shaft is bended according to the head shape and they can be shortened when not in use. This design is used to defense others’ interruption. The pointy pyramids warn others not to disturb the user in sleep; while personal space is created around the head by the expandable pyramids.
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Design 2 The design protect the user from hitting other objects while sleeping. The surrounding inflatable canopies create volume around the user and increase the privacy. The transparent canopies are denser at the back of the head to prevent user from hitting surrounding objects.
Design 3 The model acts as a barrier from the outside world, user can hide in the large shell and stay away from others. The main frame expands from the front pivot point and joins the main supporter at the back. The wired web increase privacy of the user when sleeping as others will be hard to look through the web.
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2.0 DESIGN Cheng Chi Yau Shen Yu Qian Yuki
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2.1 Design Development Intro
Aims Suitable for different sleeping positions: 1. with one arm stretching out - requirement in the length 2. with two arms under the head - require ment in width 3. with one’s head propped on the hands requirement in height
Comfortable: Provides a comfortable sleeping environment when people is sleeping on the desk. Take light and ventilation into consideration. Protective: Using round curves instead of sharp triangular structures for not being defensive to others. Private: Providing a private space and giving user sense of security.
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2.2 Design Proposal V1.1
PERSPECTIVE
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FRONT
The structure a set of half ovals in different sizes with different density. The circles above the head are larger and denser to ensure privacy; while the circles at the front are smaller to remain private and allow ventilation and lighting at the same time. 800 mm 200 mm
The structure is improved by extending it from the shoulders to the back which increases personal space and blocks light from the back as well. The sleeping pod can be dragged both vertically and horizontally to fit different body sizes of users and sleeping positions.
150 mm 600 mm Transformation of the model
The skin can be fabric which is good in tension and provides low transparency to cover the user in sleep.
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2.2 Design Proposal V1.2
PERSPECTIVE
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ELEVATION
Problems: 1. Need support on neck; 2. Need support on back; 3. The bag is insecure. Support the neck and back with cushions to create comfortable resting place.
Design the side structure like this and provide a curtain to block light and ensure privacy.
Design the bottom part in curve to create volume for storing personal belongings. The curve can protect the belongings as well.
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2.3 Precedent Research Burnham Pavilion - Zaha Hadid Architects The pavilion is composed of a bent aluminum structure as the frames (bones) of it and each rib is shaped and welded to create an oval-shaped shelter.
The inner and outer fabric skins are wrapped tightly around the frames to form a pavilion and also act as the screen for video installations.
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The shape of the pavilion inspires us to form our design with simple oval-shape frame and covered by smooth skin. We change the shapes into vertical ovals and a more circular shape in the side view.
Originally we tried to used straws as the main frames but it is not strong enough, the pavilion with metal frames inspired us to use metal wires as the frames to increase strength.
We remove the holes on top, reduce the size of hole and move it to the back of the structure so that the interior can be darker.
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2.4 Design proposal V2
FRONT
PERSPECTIVE SIDE
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Version 2.1 The vertical straws are thicker in the middle to allow light and ventilation, thinner straws on two sides increase privacy.
The strings is more dense at the top and on two sides of users’ face to block direct light and increase privacy while sleeping. The bottom part, front and back of the sleeping pod has higher transparency to allow ventilation and user can observe what’s happening outside the structure.
Version 2.2
This version is more defensive which covered with different sizes of straws. Straws at the top is placed vertically to warn others not to disturb the user. Straws are placed horizontally on two side; when the sides are expanded, there will be gaps between each straws to allow ventilation.
This version is a barrier that blocks disturbances from outside, covered with overlaying strings in different density. The use of thread to form skin allows penetration of light and ventilation which create a comfortable environment to sleep in workplace.
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2.5 Prototype
For the final design, we decided to use version 2.2 - straws as the skin. Straws at the side and top are placed vertically to allow better ventilation and light penetration. The bottom part of the structure is covered by vertical expandable straws to allow the changes of height and size. The most bottom part is covered by thinner straws to lower the transparency and increase privacy inside the sleeping pod.
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The bone structure is strengthened by wire and covered by cut straws. All the straws are fixed with invisible strings to allow movement when changing the shape/size of the structure.
LIGHTING
EXPANDABILITY
2.6 Testing Effects
The person can be fully covered within the sleeping pod; the shape of it is changeable and flexible enough for different position. The straws skin can provide a personal space for her to rest. Yet, the structure may not be rigid enough as the skin with straws are heavier than the bones, the structure may collapse when changing the shape.
Direct light from the top are blocked by the straws while soft light can still pass through the straws to create a cosy environment for nap. Hole within each straws and gaps in between the vertical straws allows good ventilation.
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3.0 FABRICATION 26
Cheng Chi Yau Shen Yu Qian
3.1 Introduction
The aims of the sleeping pod is to provide a comfortable and private space for the user to rest, taking light and ventilation into consideration. It can be expanded in three directions, i.e. height, width and length in order to fit different sleeping positions and different body shapes. Straws are used as the bones and skin of the model, white and blue are the two main colours to create a darker environment on two sides. In this module, we will focus on the form of the skin and the mechanism of the expandable part.
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BONE
3.2 Design Development & Fabrication - Prototype V2
Thus, we have made some adjustment to solve the structural problems. 1. Circular-bones increase from 7 to 10 to increase complexity. Each bones is strengthened by adding 2 wires instead of one. 2. Wires are added on both sides to make the model more rigid. 3. Expandable part reduced to one area to increase strength.
SKIN
In the M2 prototype, there are 2 main structural problems that need to be fixed. 1. Whole model is not rigid enough to stand; 2. junctions of the expandable part is weak 3. the form is too simple.
For the skin, there are only one thickness of straws with regular length. In order to create more defined volumes and sense of personal space, 1. length of the straws increased at the top of the model; 2. there will be two thicknesses of straws on the upper skin, with a thicker one enveloping a thinner one.
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section
Expandable part: Straw on it is sewed on the skin of another half-cut straw instead of passing through the whole straw so that the inner straw can be compressed into the outer straw without being blocked by the knots.
JUNCTION
The attached straw are cut at the connection part to envelop another straw. After fixing the position, invisible strings and needles are used to sew the junction.
section
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The two attached straw are cut at two end. Overlap and sew them at the middle of the overlapping area. String passes through the whole structure to fix the position.
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Rhino Model
3.2 Design Development &Fabrication - Prototype V2
SIDE
FRONT
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PERSPECTIVE
Protorype V2 We tested the skin in prototype V1. The diagrams show the difference between the previous and current prototype’s skin. The disparity of lengths and thickness of straws increase to create volumes within the skins. The longer and thicker transparent straws on the top allow ventilation and light to come in. They also increase the defensiveness to warn others not to disturb the user. The straws gradually change from transparent to blue; darker, denser and smaller straws increase sense of personal space at the bottom.
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3.3 Design Development & Fabrication - Prototype V3
JUNCTION
In the V2 prototype, there are 2 main structural problems that need to be fixed.
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1. The junction areas buckle when more straws are sewed on the skin. At the cross junction, only one wire can pass through. Due to heavy weight and weak support, the structure broke at the junction and collapsed.
To strengthen the junctions, we cut 2 extra straws with a hole in the middle. Then use them to envelop the junction so that the vertical straw will not bend too much.
2. The junctions of expandable part break easily. The junctions with half-cut straw enveloping a complete one are weak.
we changed the arrangement, where the half-cut straw is enveloped by a complete straw to reduce the possibility of breaking.
When loads increase, the structure tends to collapse from the middle part of the structure horizontally .
STRENGTHENING
To increase stability, we added two pieces of wood at the front to fix the shape. We added two pieces of wood at the bottom of both sides to effectively carry loads and increase strength.
We also use double- twisted wires to make the noggings between each circular bone; as well as to connect the first curve and the second curve. For aesthetic effect, we envelop the wires at the front with straws.
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BONE
3.3 Design Development & Fabrication - Prototype V3
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For the circular bones which are supposed to support the skin above, we found that only straw itself is not able to carry loads and form a stable shape because it will be reshaped easily. When too much loads are laid on the straw, it buckles easily
So at first we put one single wire into the straw to increase rigidity. However, when loads increase, the structure tends to collapse and the shape of the curve can not be fixed.
Then we double the wires by twisting them together. The structure is stronger than before but will still be reshaped when loads increase.
We tried twisting the wires around the straw. The structure is stable with half skin covered. However, there is still possibility of collapsing when another half structure is covered with straws.
Finally, we useed the double twisted wires to make a cross at the top of the curve. The structure then becomes much stronger.
EXPANDABILITY Height Height can be adjusted from 45 cm to 50 cm, which is less than initial design (increase at least 8 cm). Height is limited by the 2 trapezoid supports. It can not be compressed fully yet it can still In order to provide a more rigid structure, be altered to suit different users’ body sizes. the top few expandable straws were Length changed to non-expandable straws with The model can be lengthened for 7cm, from 70 cm to 77 cm. It doubled-wires. Thus, the expandable nearly meet the initial design, which can be lengthened by 10 part reduced. cm. The height and length of prototype V3 can be adjusted through expandable straws to fit different body sizes and sleeping positions.
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3.4 Final Prototype Development & Optimisation
SUPPORTINGS
Since the skin is too heavy, after applying wires and wood to it, it is still not rigid enough. Thus, we tried to work out a structure inside the pod to give support to the back part. We made 2 supports in trapezoid shape, which stands on the table, to support the heavy skin. They were connected at the bottom to avoid slipping and moving with the pod. Wooden sticks, which is good in compression and can effectively transfer loads, are used as the major supporting component. At both ends, wires are twisted around the wood sticks and extend a little bit. One side is to make connections with the pod and another side is to fix with another supporter.
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The wooden boards at the front are replaced by double-wires enveloped by thick blue straws. Using of straws unify the materials and overall look. They are fixed in cross to increase the stability.
MATERIAL
The top of the curve is fixed but the bottom is not stable, so we use double twisted wires to make some’noggings’ to connect neighbouring curve bones and avoid twisting. Some of the wires noggings on two sides were originally exposed. They are now covered by blue straws to improve the appearance of the skin.
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EFFECT
At the top of the model, we used the longest transparent straws to create the skin. There are three kinds of components, i.e.1.1cm straws, 1.1 cm straws enveloping 0.6 cm straws, and 0.6 cm straws, with all around 7-8 cm long.
At the middle part of the model, we used the second longest straws. Again, there are three kinds of components, i.e. 0.6 cm transparent and blue straws, and 1.1 cm transparent straws enveloping 0.6 cm blue straws, with all around 5-6 cm long.
At the bottom part of the model, we used the shortest straws instead of wooden board to unify the materials. There are two kinds of components, i.e. 0.6 cm blue straws, and 1.1 cm blue straws enveloping 0.6 cm blue straws, with all around 3-4 cm long.
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3.5 Final Digital Model We use Rhino to do the initial design. It is easier to adjust the height and length to fit the body well compare with fabricating the model by hand. Among all the digital fabrication methods introduced by Kolarevic (2003), we have thought of using additive fabrication to build up the extension part of the sleeping pod. Rhino files in plan and section can be used for the 3D printing. Yet, due to the limitation of materials, using 3D printing to print out all the straws or the bones will not be cost and time efficient. There is also no suitable digital fabrication machines for straw editing in the fablab.
PERSPECTIVE
SIDE
Thus, due the cost, time and materials limitation, we decided not to use digital fabrication to build our model and focused on hand-making.
DETAILS
DETAILS
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3.6 Fabrication Sequence 1. made one side of the frame with one wire inside each horizontal bone. 2. made the extension part. 3. compared two sides of the model and made adjustments. 4. added doubled-wire into each vertical bones. 5. combined the bones and formed the circular bones on top. 6. folded the frames into half in order to find the middle points of it. 7. added the top bone with wire. 8. covered half of the prototype with straws; strengthened with wires across the frames. 9. sew the wooden boards on the two bottom sides and at the front.
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10. sew the expandable parts of the model with wires within them. 11. added the 2 trapezoid support. 12. tested the effect of trapezoid support by putting a bag of straws on it. 13. covered all the wires with straws. 14. covered the whole model with straws from the bottom to the top. 15. removed the wooden boards at the front and on two sides and replaced with straws.
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3.7 Assembly Drawing 1
INITIAL DESIGN
1. The top part of the skin combine of thick (1.1 cm)transparent straws and gradually change to thinner (0.6 cm) transparent straws.
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2. The middle part of the skin combine of thick transparent straws enveloping thin blue straws and gradually change to thin blue straws. 3. The lower part of the skin combine of thin blue straws and gradually change to thick blue straws.
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4. The expandable part combine of rows of vertical straws between two horizontal secondary bones. 5. The bottom part of the skin combine of thinnest and shortest blue straws.
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7. 2 extra supports in trapezoid shape are used to support the heavy skin. 8. 2 rows of doubledwire covered by straws are sewed on both side to increase stability. 9. At the front, two pieces of straws in cross and strengthened with wires are added to fix the position of the model.
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FINAL DESIGN
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6. Double-wires in cross are attached at top of each circular bones to provide strength.
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3.8 Sleeping Pod
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LIGHT
3.8 Sleeping Pod - Effects
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PERSONAL SPACE 47
4.0 REFLECTION Cheng Chi Yau
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Throughout the whole semester, I have been developing a more complete and integrated design process. From analysing an object to come up with a concept (M1), then based on the concept to brainstorm different design ideas and proposals (M2), and finally choose the best option to work out the ideas (M3). The whole process required time and efforts in order to achieve the best solutions.
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In M1, when analysing the mechanism of umbrella, only by observing the real object is not enough to come up with a detailed system diagram, I also need to do research on the internet so as to understand the system of it. In M2, one of the challenges is to combine all our ideas into one design. We have different considerations and concerns when we were designing the sleeping pod, I focused on the functionality (expandability of it to suit different sleeping positions and body sizes) while Yuki focused on the aesthetic effect (appearance of skin) of it. After having several discussions and communicating our ideas with drawings and physical prototypes, we came up with a sleeping pod that meet the our requirements. In M3, the most challenging task would be fabricating the design into real-life. Since we are using straws as the bones and skin of the whole structure, we can only use digital model to test out the effect of form and skin but not digitally fabricate the model. We spent a long time on hand-making the prototypes to test different effects of the skin and then complete the final model. Fortunately, the effect and appearance of the final prototype turned up better than we expected; yet the functionality of it may be ignored due to the limitations of materials. There is room of improvement on balancing the functions and the aesthetic effect of the design; we may need to further explore methods to solve the structural problems.
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Beside a more integrated design process, I have developed the ability of using different methods to present my ideas and designs. I have been using computer programs like Rhino, Open Office and InDesign, as well as different types of hand drawings like plan, section, perspective and assembly drawings to visualise and communicate my ideas. How to photograph my models in a delicate and clear way and showcase the key message is another skill that I have learnt throughout the whole subject. As suggested by Marble (2008 ) in Imagining Risk, “risk has a resiliency that is essential to cultural and technological progress where innovation occurs�, even though we can use technologies to digitally fabricate the model, it is only a way to test the effects of the design; we should not be limited by the digital model. Crafting and traditional ways of designing like hand drawing and model making, are always important to develop creative and innovative ideas. To further put my skills to a higher level and integrate all these skills would be my challenge in the future. I will explore and practice more on my computer skills so as to ease my design process. Lastly, time management is another important factor that needed to be considered during the whole process. Since we under-estimated the fabrication time of the model, we put most of the time on making the model and spent less time on completing the journal and preparing the presentations. Balance between different works and plan the working schedule are the best solutions to complete all the works on time.
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5.0 APPENDIX
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Bibliography Kolarevic, B 2003, Architecture in the Digital Age - Design and Manufacturing/Branko Kolarevic. Spon Press, London Marble, S, 2008. Building the Future: Recasting Labor in Architecture/ Philip Bernstein, Peggy Deamer. Princeton Architectural Press. pp 38-42 Roland Halbe, 2009, Burnham Pavilion, Zaha Hadid Architects, viewed 1 June 2016, < http://www.archdaily.com/33110/burnham-pavilion-zahahadid/57233549e58ecea67b000003-burnham-pavilion-zaha-hadid-photo> Roland Halbe, 2009, Burnham Pavilion, Zaha Hadid Architects, viewed 1 June 2016, <http://www.archdaily.com/33110/burnham-pavilion-zahahadid/5723352ae58ecea67b000002-burnham-pavilion-zaha-hadid-photo>
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