Bartlett • AD
STRUCTURAL SLIP AD Material Architecture Lab 2017-2018
project by Vittoria Fusco, Dan Liang Banni Liang, Mingyu Wei
BARTLETT PROSPECTUS
STRUCTURAL SLIP AD Material Architecture Lab (2017-2018) Tutors: Daniel Widrig, Guan Lee, Adam Holloway, Stefan Bassing and Igor Pantic project by Vittoria Fusco, Banni Liang, Dan Liang, Mingyu Wei
6
OUTLINE 0. INTRODUCTION 1. INITIAL APPROACH 2. CONCEPT: THE KEYWORDS 3. GEOMETRIC AND COMPUTATIONAL RESEARCH 4. INITIAL MATERIAL RESEARCH 5. PARAMETRIC OPTIMIZATION OF THE SYSTEM 6. GLAZE TEST AND DESIGN DEVELOPMENT 7. PRELIMINARY FABRICATION STUDIES 8. MATERIAL RESEARCH DEVELOPMENT 9. MASS PRODUCTION 10. B-PRO SHOW PROPOSAL 11. PHYSICAL PROTOTYPE 12. FINAL PROPOSAL
AD RC6 Material Consequences | UCL
7
8
0. INTRODUCTION
In architecture there are fundamentally two ways of using clay: non-structural clay, such as tiles hanging on metal frames and structural clay, such as a brick masonry. Structural clay is one of the keywords underpinning our project, as the aim is to design a 3-dimensional clay system, able to be self-supported and bear loads. Another keyword is porosity, as a potential architectural language, not only for its variable and fascinating aesthetic value, but also for its functional performances of solar control, mild ventilation, internal thermal comfort and adequate level of privacy. The idea is to create a modular architectural system, which guarantees feasibility and mass production, but draws upon parametric software to pursue variety of configurations and outcomes which are always, at the same time, unique but reasonable. Such an achievement is enhanced by the exceptional qualities of the material: clay. Clay is worldwide, natural, easily accessible, cheap, highly fireproof, and absolutely sustainable, not only as the material itself but also in its manufacturing procedures. Moreover, clay itself is characterized by a singular porosity, since it is porous at its raw state, allowing water through and being malleable, and it changes into non-porous after a firing process, becoming hard and resistant.
AD RC6 Material Consequences | UCL
9
The initial approach is characterised by our attempts to explore more deeply the world of clay with its different techniques and define a design strategy which permits at the same time mass production, variability and unicity, achieving an extremely appealing visual effect. Furthermore, we study possible ways to optimize the use and the connections between components and techniques.
10
1. INITIAL APPROACH 1.1 Initial Concept 1.2 Mass production 1.3 Design of the variation 1.4 System studies 1.5 Material studies
AD RC6 Material Consequences | UCL 11
1.1 INITIAL CONCEPT
Combine different clay techniques in one system to create the variation of the visual effect
DIFFERENT CLAY TECHNIQUES
BRICK SYSTEM
3D PRINTING
+
STRUCTURAL FUNCTION
12
VARIATI
SLIP CASTING
+
VISUAL EFFECT
ACCURATE CONNECTIONS
The Robotic Fabri
ION OF VISUAL EFFECT
ication LAB at The University of Hong Kong
MASS PRODUCTION
The Bartlett 3D printing clay fabrication
AD RC6 Material Consequences | UCL 13
1.2 MASS PRODUCTION
The combination of the 3D printing components with the same curvature
All the surfaces in this diagram are with the same curvature so that they can be fabricated by the same mould. We used parametric tools to make variation of the visual effect when they are conbined togather. You can see a continuous fluctuant wall when the components are conbined together.
B
A
Instruction
A.Components with different shape but the same curvature can be fabricated by the same moud B.Componets with different curvature can be fabricated by the specific mould with different curvatures
14
Assemble the components on the wood structure
AD RC6 Material Consequences | UCL 15
1.3 DESIGN OF THE VARIATION
Create different 3D printing components by limited number of moulds
The posibilities of the variation of the wall which made by the components with the same curvature
16
The posibilities of the variation of the wall made by the components with the multiple curvatures
0
15
30
45
60
75
90
105 120 135 150 165 180 The curvature of the surfaces are under
Different curvature of 3d printing components
the control of the parametric tools. In this diagram, each colour represent one curvature. There are 12 colours in this diagram, it means ii can be fabricate by at most 12 moulds
AD RC6 Material Consequences | UCL 17
1.4 SYSTEM STUDIES
Slip casting+3D printing
Slip Casting Connections
3d printed surfaces
bars or sticks
Strengths
• Flexibility for the structure • Combination of casting and 3d printing • Use of the toolpath to make connections
Weaknesses
• Use of sticks • Different moulds to create different surfaces • Low tollerance system
18
Slip Casting Connections
Joint Interlocking system
3d printed surfaces
Insert
Strengths
• Combination of casting and 3d printing • Structure made by cast bricks • Use of the toolpath to make the connections • Structure working under compression forces • Same mould to create different surfaces • High tollerance system
Weaknesses
• Low tollerance system • Accuracy of the corresponding surfaces because made only by casting
AD RC6 Material Consequences | UCL 19
1.4 SYSTEM STUDIES
Slip casting+3D printing
Slip Casting brick
Interlocking system
Hole created by toolpath to allow connection
3d printed surfaces
Slip Casting brick
Strengths • Combination of casting and 3d printing • Use of the toolpath to make the connections • Compression system • Same mould to create different surfaces
Weaknesses
• Low tollerance system • Less accuracy because of the 3d printed surfaces
20
Slip Casting brick
3d printed surfaces
Strengths
• Combination of casting and 3d printing • Integration of structure, connection and visual effect design • Flexibility of the structure thanks to cast bricks • 3d printed component as structure, connection and visual effect • Compression system • Same mould to create different surfaces • High tollerance system • More accuracy thanks to cast bricks
AD RC6 Material Consequences | UCL 21
1.4 SYSTEM STUDIES
Overcome the limitation of 3D printing surface components
A
Instruction
A.The fragility of the surface components B.Conbine two components to make it more stable C.The assambling of the component. D.The combination of two components using morta E. the assambling of differentcomponents
22
B
C
Strengths
D
• The system has the potential to overcom the frafibility of the components • The variation of the visual effect is appealing • the diamond-shaped components has the potential to develop the interlocking system
E
Weaknesses
• This system is hard to envolve 3D printing and slip casting at the same time • the compomnent is hard to fabricate since it need large number of moulds
AD RC6 Material Consequences | UCL 23
1.5 MATERIAL STUDIES
Study of the fabrication of the 3D printing surfaces
24
AD RC6 Material Consequences | UCL 25
1.5 MATERIAL STUDIES
The study of 3D printing surfaces
Nozzle Mould
Nozzle Mould
12 mm
12 mm 12 mm
12 mm 14-16 mm
Based on the situation we meet from the mistake, we changed the height of nozzle in order to avoid roughness of the sharp edges and optimize the weaving curves.
3 axes weaving pattern printing: toolpath
26
Interesting weaving pattern
3 axes weaving pattern printing: toolpath
AD RC6 Material Consequences | UCL 27
1.5 MATERIAL STUDIES 3D printing tests
We are also able to control the variation of the pattern in one single component by control the variation of the toolpath
28
Noise pattern
3 mm
Noise pattern
3 mm
Branch weaving
5 mm
Cross weaving
3 mm
Study of the control of the variation in one component by using curl-noise
AD RC6 Material Consequences | UCL 29
1.5 MATERIAL STUDIES 3D printing tests
We tried to study the control of different surface texture. The outcome is usually more interesting than the toolpath because of the material behaviour of the clay.
The toolpath of weaving pattern
30
Weaving brick
5 mm
Cross weaving
5 mm
Branch weaving
7 mm
Cross weaving
5 mm
Cross weaving
Branch weaving
5 mm
Cross weaving
3 mm
Lattice
5 mm
3 mm
AD RC6 Material Consequences | UCL 31
According to the results and the understanding derived from the initial studies and tests we want, at this point, to make clear the guidelines and the keypoints which underpin all our design research and will lead us to achieve our scope: develop a unique architectural design, based on the advantages of such a natural and eternal material and able to guarantee realistic feasibilty in terms of cost, time, production, sustainability, maintenance.
32
2. CONCEPT: THE KEYWORDS 2.1 Material Constrains 2.2 Porosity 2.3 Different Clay Techniques 2.4 Proposal
AD RC6 Material Consequences | UCL 33
2.1 MATERIAL CONSTRAINTS
NON-STRUCTURAL CLAY
1
3
2
STRUCTURAL CLAY
4
1.Mihrab of Sheikh Lotfollah Mosque, Isfahan, Iran 2.DarwenTerracotta, English pub, Islington 3.Exeter Library, Louis Kahn, New Hampshire 4.Casa Kimball, Rangr Studio, Dominican Republic
34
NON-STRUCTURAL CLAY Tiles hanging on metal structure
2D components not touching each other for the tramsission of loads
NO LOAD-BEARING SKILL NO LOADS TRASMISSION
STRUCTURAL CLAY Bricks overlapping with each other
solid components touching each other for the trasmission of loads
LOAD-BEARING SKILL LOADS TRASMISSION
AD RC6 Material Consequences | UCL 35
2.2 POROSITY
The function of porosity
The hollow wall which havs porocity itself can provide two main functions: cooling down the temperature and creating light effects.
Cool air
Warm air
COOLING
Light
SUNLIGHT
36
COOLING
1
SUNLIGHT
2 1.Example of typical cool homespace, veranda 2.Example of the effect of sunlight passing through a porous wall
AD RC6 Material Consequences | UCL 37
2.3 DIFFERENT CLAY TECHNIQUES
3D PRINTING
SLIP CASTING
Ceramic Morphologies, Harvard University
Icebarg, ceramic art, Jonathan Keep
Accuracy
Time of production Cost of production Aesthetic value Sustainability
38
Matt Davis ceram
Accuracy
Time of produc
Cost of produc
Aesthetic value Sustainability
mics
ction
ction
e
COMPRESSION
Tectonic Horizons, Data Clay
blog, Lacey Green
blog, Lacey Green
Accuracy
Time of production Cost of production Aesthetic value Sustainability
AD RC6 Material Consequences | UCL 39
2.4 PROPOSAL
Combination of 3D structural clay using different techniques to create porous architectural systems
3D STRUCTURAL DISCRETE COMPONENTS
POROSITY
+
40
DIFFERENT TECHNIQUES
+
+
AD RC6 Material Consequences | UCL 41
The geometric study is characterised by the research of a simple and modular starting geometry in order to guarantee the ease in the fabrication process. The computational investigation aims to study more complex and unique ways to combine the simple geometry in a multiplicity where the variability and originality is from time to time guaranteed by parametric control.
42
3. GEOMETRIC AND COMPUTATIONAL RESEARCH 3.1 Discrete component from the Rubik Cube
3.1.1 Discrete component possibilities from one Rubik Cube 3.1.2 Parametric control of assembling and porosity: Random growth
3.2 The logic of the module from the Soma Cube 3.3 Porosity within the module with Polycube
3.3.1 Generate porosity within one module 3.3.2 Parametric control of assembling and porosity: Random reduce 3.3.3 Parametric control of assembling and porosity: Shortest walk
3.4 Control of porosity with the Marching Cube
3.4.1 The logic of Marching Cube 3.4.2 Control and complexity with the Marching Cube algorithm 3.4.3 Parametric control of assembling and porosity: Curl-noise 3.4.4 Variation of porosity with Curl-noise
3.5 Design more complex geometries
AD RC6 Material Consequences | UCL 43
3.1 DISCRETE COMPONENTS FROM THE RUBIK CUBE
3.1.1 Discrete components possibilities from one Rubik Cube
Starting from the awarness of the limits of traditional clay bricks, in terms of geometry and aesthetic value, the design research has been oriented towards finding an ideal component which would be at the same time repeatable and aesthetically precious and would attribute three-dimensions to the overall geometry. For this reason, the Rubik’s Cube represented the first appropriate geometric reference. Rubik’s Cube is a 3D combination puzzle invented in 197 by Hungarian sculptor and professor of architecture Ernő Rubik. It consists of twenty-seven unique miniature cubes whose external faces are covered by nine stickers, each of one of six solid colours. Through an internal pivot mechanism which enables each face to turn independently, the colours are mixed up. For the puzzle to be solved, each face must be returned to have only one colour. The logic of Rubik’s Cube, and more specifically the different colours of the single faces, allowed us to explore and recognise all the possible aggregations of the miniature cubes, which strictly depend on the number of miniature cubes considered at a time.
44
1
2
3
4
5
6
7
8
9
10
Possibilities of components depending on the number of cubes used
AD RC6 Material Consequences | UCL 45
3.1.2 PARAMETRIC CONTROL OF ASSEMBLING AND POROSITY Random growth of components from multiple points
STARTING GEOMETRY
LOGIC OF ASSEMBLING Finding the top surfaces randomly to guarantee at least one surface overlapping the previous component.
CHANGING PARAMETERS
46
SCRIPT
Ramdom growth from the starting geometry
AD RC6 Material Consequences | UCL 47
3.2 THE LOGIC OF THE MODULE FROM THE SOMA CUBE A limited number of components and combinations
The Soma Cube represents the second reference in the geometric research of the basic component. The Soma cube is a solid dissection puzzle invented by Piet Hein in 1936 during a lecture on quantum mechanics conducted by Werner Heisenberg. Seven pieces made out of unit cubes must be assembled into a 3×3×3 cube. The pieces of the Soma cube consist of all possible combinations of three or four unit cubes, joined at their faces, such that at least one inside corner is formed. There is one combination of three cubes that satisfies this condition, and six combinations of four cubes that satisfy this condition. The number of solutions of the cube puzzle is 480, but in fact they are evenly divided into 240 configurations and their 240 mirroring images. The logic of the Soma Cube allowed us to select a limited and more manageable number of components among a substantial quantity of components derived from the Rubik’s Cube. Moreover, it lead us to work no longer with a single compo-
48
Some of the 240 solutions of Soma cube
AD RC6 Material Consequences | UCL 49
3.3 POROSITY WITHIN THE MODULE WITH THE POLYCUBES 3.3.1 Generate porosity within one module
POROSITY ONLY INSIDE THE MODULE
BAIOCCHI FIGURES FOR POLYCUBES
The next step of the geometric research aimed to create porosity not only by decreasing the number of components in the overall design but, more efficiently, controlling it within the single modules which generate the overall geometry. For this reason we oriented our research, concerning polycubes geometries, towards a specific type of polycubes, Baiocchi Figures applyed to Besźel Polycube. A polycube is a solid figure formed by joining one or more equal cubes face to face (for example the Soma Cube). A Besźel Polycube is a polycube whose cells all have at least two even coordinates. A Baiocchi figure is a figure formed by joining copies of a polycube and having the maximal cubic symmetry for the polycube’s class. By studying the minimal known Baiocchi figures for Besźel Polycubes of orders 1 through 5 (Monocube, Dicube, Tricubes, Tetracubes, Pentacubes, Hexacubes) we found the opportunity to create porosity within each cube module in order to better control and create variable porosity in the overall design.
50
COMPONENTS
ROTATE & COMBINE
POROSITY
+
+
-
+
+
-
+
+
-
+
+
-
+
+
-
POROSITY INSIDE AND ALONG THE EDGES OF THE MODULE
COMPONENTS
ROTATE & COMBINE
POROSITY
COMPONENTS
ROTATE & COMBINE
POROSITY
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
AD RC6 Material Consequences | UCL 51
3.3.2 PARAMETRIC CONTROL OF ASSEMBLING AND POROSITY Growth of modules inside a regular grid
Using Random Reduce to assemble the modules
STARTING GEOMETRY
CHANGING PARAMETERS
52
LOGIC OF ASSEMBLING
SCRIPT
Random reduce to create the porosity
AD RC6 Material Consequences | UCL 53
3.3.3 PARAMETRIC CONTROL OF ASSEMBLING AND POROSITY Growth of modules inside a regular grid
Using Shortest Walk to assemble the modules
STARTING GEOMETRY
CHANGING PARAMETERS
54
LOGIC OF ASSEMBLING
SCRIPT
Creating the porosity under the control of shortest walk to ensure the overlapping of the components
AD RC6 Material Consequences | UCL 55
3.3.3 PARAMETRIC CONTROL OF ASSEMBLING AND POROSITY Growth of modules inside a regular grid
+
+
BASIC COMPONENT
56
+
BASIC MODULE
+
+
CUT COMPONENT
+
CUT MODULE
AD RC6 Material Consequences | UCL 57
3.4 CONTROL OF POROSITY WITH THE MARCHING CUBE 3.4.1 The logic of Marching Cube
Marching cube is a computer graphics algorithm for creating a polygonal surface representation (2D surface mesh) of an isosurface of a 3D scalar field. It is meant to 3D model an object whose shape is not known in advanced. The fundamental problem is to form a facet approximation to an isosurface by testing wether the points of a rectangular grid are below or above the isosurface. Given one grid cell (cube) defined by its vertices and scalar values at each vertex, it is necessary to create planar facets that best represent the isosurface through that cube. The isosurface may not be pass through the cube or it may cut off some or all the vertices. Each possibility will be characterised by the number of vertices that have values above (0) or below (1) the isosurface. Since each cube has 8 vertices we will get 2⁸ = 256 different combinations. If one vertex is above the isosurface and an adjacent vertex is below the isosurface then we know the isosurface cuts the edge between these two vertices. The position that it cuts the edge will be linearly interpolated. What makes the algorithm “difficult” are the large number (256) of possible combinations and the need to derive a consistent facet combination for each solution so that facets from adjacent grid cells connect together correctly.
128
V8 16
V5 V7 V6
64 V6
V4
V1
32
V1 V3
V3
V2
Each vertix has 2 possibilities: 0 = above or outside 1 = below or inside
V2
Isosurface facet
Vertex 2 = below Other vertices = above
8 vertices per cube
This results in a binary number of 01000000 or 2¹ = 2
2⁸ = 256 different combinations
V1 V2 V3 V4 V5 V6 V7 V8 0 1 0 0 0 0 0 0
1
4 2
Then, each vertex can be expressed by a similar binary number. The sum of the binary numbers of all the points below the surfaces equals the number of the combination.
PRINCIPAL APPLICATION OF MARCHING CUBES ALGORITHM
MRI scans
58
Metaballs
8
3D contour of a mathematical scalar field
128
128
16 32 1
2
64
64
8
4
2
128
4
2
128
32
2
8
2
128
4
8
1
2
4
2
128
2 16
32
8
1
4
8
1
16 32 1
8
4
2
64
8
2
8
1
4
2
64
16
1
8
4
By using symmetry and rotation it is possible to reduce the 256 cases to only 15.
AD RC6 Material Consequences | UCL 59
3.4.2 CONTROL AND COMPLEXITY WITH THE MARCHING CUBE ALGORITHM Way of utilization of marching cube logic in the design research
Although the Baiocchi Figures applyed to polycubes allow us to create porosity inside the module generating the overall structure, it does not permit a more complex porosity and within the singol module and full control of it within the overall design. For this reason, we studied the Marching Cubes algorithm which enabled us to create more variable cube modules and define different porosities both within them and inside the overall design. Through the logic of Marching Cubes we can create voids not only either the internal part of the marching cube modules or the matter along edges and cornes, but we can decrease the quantity of components (and so material) in different parts of the volume of the cube module. However, we do not use Marching Cubes logic only to design complex porosity in the single modules. Most importantly, the Marching cube algorithm allow us to design porosity, defining predetermined pattern of the overall structure and making the single marching cube modules accurately follow it by contolling their external vertices. This logic consists in creating a pattern represented by surfaces within a regular grid of points, of the same dimensions as the cube modules, which define the overall structure. Through analysing wether the points of each single cell of the grid are above or below the surfaces, it is possible to identify the correct marching cube module corresponding to that specific cell, and place it appropriately.
Using marching cubes to create more complex geometries
60
Combining marching cubes logic with polycube geometries
AD RC6 Material Consequences | UCL 61
3.4.3 PARAMETRIC CONTROL OF ASSEMBLING AND POROSITY
Applying the marching cube logic to create a porous wall made with curl-noise
CONTROL POINTS LOGIC BY USING THE MARCHING CUBE ALGORITHM
CHANGING PARAMETERS
62
SCRIPT
Define the porosity pattern through the parametric control of curl-noise
AD RC6 Material Consequences | UCL 63
3.4.4 VARIATION OF POROSITY WITH CURL-NOISE
64
AD RC6 Material Consequences | UCL 65
3.5 DESIGN MORE COMPLEX GEOMETRIES
1
2 1.Ennis House, Frank Lloyd Wright, Los Angeles, California 2.La Miniatura, Frank Lloyd Wright, Los Angeles, California
66
Example of cut components
AD RC6 Material Consequences | UCL 67
3.5 DESIGN MORE COMPLEX GEOMETRIES
+
+
+
+
CAST MODULES WITH PATTERN POROSITY 68
+
+
3D PRINTED MODULES WITH PATTERN
+
+
+
+
+
+
CUT MARCHING CUBES
BASIC MARCHING CUBES POROSITY
AD RC6 Material Consequences | UCL 69
3.5 DESIGN MORE COMPLEX GEOMETRIES
+
+
POROSITY 70
+
+
+
+
POROSITY AD RC6 Material Consequences | UCL 71
3.5 DESIGN MORE COMPLEX GEOMETRIES The final geometry
In the diagrams below the processes which led to define the final geometry are shown. By drawing linear patterns on the basic rectangular module we ended up transforming the patterns into the geometry itself, deleting all matter outside and around the patterns and, therefore, achievieng a more complex geometry and porosity.
72
BASIC MODULE
BASIC MODULE WITH PATTERN
INSTABILITY OF COMPONENTS
ADD SUPPORTING COMPONENTS
NEW PATTERN
INCREASE OF POROSITY BY CUTTING MORE
MAKE THE GEOMETRY FOLLOW THE PATTERN
OPTIMIZE THE STABILITY BY INCREASING THE TOUCHING SURFACES
AD RC6 Material Consequences | UCL 73
3.5 DESIGN MORE COMPLEX GEOMETRIES
In the diagrams below the processes which led to define the final geometry are shown. By drawing linear patterns on the basic rectangular module we ended up transforming the patterns into the geometry itself, deleting all matter outside and around the patterns and, therefore, achievieng a more complex geometry and porosity. We also tried to combine the final geometry together with the previous ones to understand what kind of effect and overall porosity we could obtain.
+
+
+
POROSITY
+
+
POROSITY
74
+
AD RC6 Material Consequences | UCL 75
3.5 DESIGN MORE COMPLEX GEOMETRIES
76
AD RC6 Material Consequences | UCL 77
The material research aims to understand properly the behaviour of the material after each step of the fabrication process. Since the fabrication process is different for each techniques, we can highlight the advantages and the outcomes deriving from each technique’s process in order to be able to define the most appropriate usage of the components from each technique.
78
4. INITIAL MATERIAL RESEARCH 4.1 Fabrication 4.2 Comparation 4.3 Connection
AD RC6 Material Consequences | UCL 79
4.1 FABRICATION
80
AD RC6 Material Consequences | UCL 81
4.1 FABRICATION
3D printing texture research
3D printing is suitable for creating nice texture by contour crafting. Due to the specific geometry, we only use 3 axis 3D printing for fabrication.
Printing of surface texture
82
1. Base texture
2. Inner bridge
3. Surface texture
AD RC6 Material Consequences | UCL 83
4.1 FABRICATION
Different fabrication strategies
In terms of the shrinkage, we conducted a series of tests including hollow bricks,bricks with inner bridges and bricks with inner lattices.
COMPONENT A
Hollow bricks
Inner bridges Printing of component A with inner bridges
Printing of component B with inner bridges
84
Inner lattices
COMPONENT B
Hollow bricks
Inner bridges
Inner lattices
AD RC6 Material Consequences | UCL 85
4.1 FABRICATION
Slip-casting mould making
I n order to test slip casting , we made the positive geometry of our prototype by CNC, then we used woodboard to separate different parts of the negative, pour plaster into the bounding box in turn. Due to the fluidity of the liquid plaster, we can make sure each part of the mode will perfectly match each other.
Materials used to make the moulds
High density form
Polyfiller
Varnish
Vaseline
Wood glue Pottery plaster
Pieces of the positive model of our components made by CNC
86
1. Vanish the positive model
2. Create the boundaries
3. Mix plaster
4. Cast plaster
5. Cast plaste and let it dry
6. Outcomes
AD RC6 Material Consequences | UCL 87
4.1 FABRICATION
Slip-casting fabrication
The material we use for the slip-casting tests is earthernware,the most important procedure is partial drying, which is the time we spent between pouring the slip inside the mould and draining . By control the time of partial drying, we can control the thickness of the slip casting brick.
Slip-casting
88
1.Mix the slip
2.Pour the slip in
3. Pour the slip out
4. Partial drying
5. Take the mould apart
6. Outcomes
AD RC6 Material Consequences | UCL 89
4.1 FABRICATION
Compression mould making We used woodboard to make the mould to conduct the research.
Materials used to make the moulds
Wood board
Wood glue
Wooden pieces made by CNC
90
Wood filler
Assembled mold
Varnish
COMPONENT A
COMPONENT B
1. Moulds' pieces
2. Vanish and spread talco powder on the mould
3. Assemble the mould
4. Outcomes
AD RC6 Material Consequences | UCL 91
4.1 FABRICATION
Compression fabrication
Pressed clay is a particular technique which consist in pressing dryer clay mixed together with sand and grog into a mould. We did hand compression to test this fabrication method. The quality of the outcome depends on the procedure of compression and mould releasing.
Compression
92
COMPONENT A
COMPONENT B
1.Mix the special clay for compression
2. Apply the release agent
3. Hit the clay into the mould
4. Outcomes AD RC6 Material Consequences | UCL 93
4.2 COMPARATION 3D printing
BEFORE FIRING
Component A
Type 1
Type 2
Type 3
789 g
958 g
1176 g
Fabrication time Drying time Shrinkage Strenght Weight
94
Component B
Type 1
Type 2
Type 3
Fabrication time Drying time Shrinkage Strenght Weight
843 g
995 g
1320 g
AD RC6 Material Consequences | UCL 95
4.2 COMPARATION 3D printing
AFTER FIRING
Component A
Firing time Firing temperature
Type 1
Type 2
18 hours
18 hours
1000 C
1000 C
695 g
838 g
Shrinkage Strenght Weight
96
Component B
Firing time Firing temperature
Type 1
Type 2
Type 3
18 hours
18 hours
18 hours
1000 C
1000 C
1000 C
715 g
858 g
1194 g
Shrinkage Strenght Weight
AD RC6 Material Consequences | UCL 97
4.2 COMPARATION Slip-casting
BEFORE FIRING
Component A
Time for partial drying
Time before draining: 17 minutes
Time before draining: 17 minutes
Time before draining: 25 minutes
1 hour
3 hours
3 hours
538 g
560 g
648 g
Time for final drying Thickness Shrinkage Strenght Weight
98
Component B
Time before draining: 17 minutes
Time before draining: 25 minutes
3 hours
3 hours
544 g
638 g
AD RC6 Material Consequences | UCL 99
4.2 COMPARATION Slip-casting
AFTER FIRING
Component A
Time for partial drying Time for firing Firing temperature
Time before draining: 17 minutes
Time before draining: 17 minutes
Time before draining: 25 minutes
1 hour
3 hours
3 hours
18 hours
18 hours
18 hours
1000 C
1000 C
1000 C
466 g
486 g
562 g
Shrinkage Strenght Weight
100
Component B
Time before draining: 17 minutes
Time before draining: 25 minutes
3 hours
3 hours
18 hours
18 hours
1000 C
1000 C
472 g
566 g
AD RC6 Material Consequences | UCL 101
4.2 COMPARATION Compression
BEFORE FIRING
Component B
First test
Second test
Third test
Use of talco powder
No
Yes
Yes
Use of vaseline on the mould
No
No
No
Dampness of clay Proportion of clay-sand-gravel
6-1-1
5-1-1
1478 g
1502
5 - 1.5 - 1.5
Time for partial drying Accuracy Hardness Divergence from the model Weight
102
1527 g
Fourth test
Component A
First test
Second test
Yes
Yes
Yes
Yes
No
Yes
5 - 1.5 - 1.5
5 - 1.5 - 1.5
5 - 1.5 - 1.5
1728 g
1668 g
1764 g
AD RC6 Material Consequences | UCL 103
4.2 COMPARATION
3D printing & Slip casting & Compression SINGLE COMPONENTS BEFORE FIRING Component A 3D PRINTING
Drying time Bending Shrinkage Accuracy Strenght Weight
104
SLIP-CASTING
COMPRESSION
Component B 3D PRINTING
SLIP-CASTING
COMPRESSION
Drying time Bending Shrinkage Accuracy Strenght Weight
AD RC6 Material Consequences | UCL 105
4.2 COMPARATION
3D printing & Slip casting & Compression
THE MODULE AFTER FIRING
3D PRINTING
Accuracy of connections Accuracy of boundaries Stability Divergence from the model
106
SLIP-CASTING
Accuracy of connections Accuracy of boundaries Stability Divergence from the model
AD RC6 Material Consequences | UCL 107
4.3 CONNECTION
Glue test without bars
Glue
Designed system
Brick
Materials Standard bricks
Processes
Drying time
1. Spread the glue on the matching surfaces of the two bricks
No more nails glue 2. Overlap the two stardard bricks and leave the glue to dry
24/48 hours
Accuracy Strenght
Combining the two bricks with glue
108
Mortar test without bars
Mortar
Designed system
Brick
Materials Standard bricks
Processes
Drying time
1. Make mortar by mixing cement, sand and water
Normal mortar 2. Spread the mortar onto the matching surfaces of the two bricks
3. Overlap the two stardard bricks and leave mortar to set
24/48 hours
Accuracy Strenght
Mixing mortar and combining the two bricks with it
AD RC6 Material Consequences | UCL 109
4.3 CONNECTION
Glue test with bars
Glue
Designed system Rod
Brick
Materials Standard bricks
Processes
Drying time
1. Drill a hole into the two bricks
Rods, washers and nuts 2. Cut the rods and screw on it a washer and two nuts
No more nails glue
3. Squeeze the glue 4. Overlap the two into the holes, place stardard bricks and the rod and spread the leave them to dry glue on the surfaces
24/48 hours
Accuracy Strenght
Make hole and combine the two bricks with metal bar and glue
110
Mortar test with bars
Mortar
Designed system Rod
Brick
Materials Standard bricks
Processes
Drying time
1. Drill a hole into the two bricks
Rods, washers and nuts 2. Cut the rods and screw on it a washer and two nuts
3. Make mortar by mixing cement, sand and water
Normal mortar 4. Spread the mortar onto the matching surfaces of the two bricks
5. Overlap the two stardard bricks and leave mortar to set
24/48 hours
Accuracy Strenght
Cut the mateal bar and combine the two bricks with it and mortar
AD RC6 Material Consequences | UCL 111
After comprehending the features of the components made by each technique and their real feasibility about time, costs, accuracy, weight etc. we want to go further with the computational research in order to control and optimize the whole system, in terms of structural behaviour and the pattern of porosity.
112
5. PARAMETRIC OPTIMIZATION OF POROSITY AND STRUCTURAL STABILITY 5.1 Rigid block force simulation 5.2 Porosity and structure 5.3 Structure optimization 5.4 Proposal
AD RC6 Material Consequences | UCL 113
5.1 RIGID BLOCK FORCE SIMULATION Structural analysis
CURL-NOISE PATTERN WITHOUT REINFORCEMENT BARS
Wall generated by marching cube and curl-noise The voronoi algorithm allow us to design porosity, defining predetermined pattern of the overall structure accurately follow it by contolling their external vertices.
114
Forces simulation The voronoi algorithm allow us to design porosity, defining predetermined pattern of the overall structure accurately follow it by contolling their external vertices.
AD RC6 Material Consequences | UCL 115
5.1 RIGID BLOCK FORCE SIMULATION Structural analysis
CURL-NOISE PATTERN WITH REINFORCEMENT BARS
Porosity pattern generated by curl-noise with bars for the cantilever The voronoi algorithm allow us to design porosity, defining predetermined pattern of the overall structure accurately follow it by contolling their external vertices.
116
Forces simulation The voronoi algorithm allow us to design porosity, defining predetermined pattern of the overall structure accurately follow it by contolling their external vertices.
AD RC6 Material Consequences | UCL 117
5.2 POROSITY AND STRUCTURE
Optimization of porosity: voronoi VORONOI SYSTEM
Boundary
Point cloud
Voronoi cells
T-spline mesh
COMPARATION BETWEEN CURL-NOISE AND VORONOI
Curlnoise generation
118
Voronoi generation
AD RC6 Material Consequences | UCL 119
5.1 RIGID BLOCK FORCE SIMULATION Structural analysis
VORONOI PATTERN WITH REINFORCEMENT BARS
Porosity pattern generated by voronoi with bars for the cantilever The voronoi algorithm allow us to design porosity, defining predetermined pattern of the overall structure accurately follow it by contolling their external vertices.
120
Forces simulation The voronoi algorithm allow us to design porosity, defining predetermined pattern of the overall structure accurately follow it by contolling their external vertices.
AD RC6 Material Consequences | UCL 121
5.2 POROSITY AND STRUCTURE
Optimization of porosity: voronoi
The voronoi algorithm allow us to design porosity, defining predetermined pattern of the overall structure accurately follow it by contolling their external vertices.
122
AD RC6 Material Consequences | UCL 123
5.3 STRUCTURE OPTIMIZATION Grid analysis
STRUCTURAL ANALYSIS IN MILLIPEDE
Basic Square Grid
RICArts, Mosaics - fountains & water features, Pinterest
Forces diagram
The voronoi algorithm allow us to design porosity, defining predetermined pattern of the overall structure accurately follow it by contolling their external vertices.
124
Rectangular grid
Casa Tabique, TAC Taller de Arquitectura
Forces diagram
The voronoi algorithm allow us to design porosity, defining predetermined pattern of the overall structure accurately follow it by contolling their external vertices.
AD RC6 Material Consequences | UCL 125
5.3 STRUCTURE OPTIMIZATION
Finite Element Method Analysis in Millipede
TARGET GEOMETRY
TARGET LINES
STRESSED PART
FEM RESULT
More stressed
126
Less stressed
PICK THE MOST EFFICIENT GEOMETRY
The configuration of the wall with its porosity pattern is determined by the different placement of the modules. This collocation is decided and optimised by the parametric control of millipede which choose the most appropriate of the 6 rotations of the module, according to the distribution of the forces and the most stressed areas.
AD RC6 Material Consequences | UCL 127
5.3 STRUCTURE OPTIMIZATION Structure Analysis: Karamba
Compressive stress
RTension
RRandom pattern of the brick
128
Compressive stress
RTension
tRThe pattern after optimization
AD RC6 Material Consequences | UCL 129
5.4 PROPOSAL
Our proposal is developing the language of porosity under parametric control by using parametres related to structure, light , environment.etc. Through the material research, we could understand the potential of each technique and find a solution to conbine them in our system.
130
AD RC6 Material Consequences | UCL 131
5.4 PROPOSAL
Software for parametric modelling, such as Grasshopper, allow us to design and control any kind of variations, transition and disquiet by using points or lines working as attractors. It is also possible to design the flow of the entire wall or architectural facade by using plugin such as Anemone and Kangaroo and create within it both punctual and complex variations.
132
AD RC6 Material Consequences | UCL 133
5.4 PROPOSAL
134
AD RC6 Material Consequences | UCL 135
5.4 PROPOSAL
136
AD RC6 Material Consequences | UCL 137
Ceramic glaze is an impervious layer or coating of a vitreous substance which has been fused to a ceramic body through firing. Glaze can serve to color, decorate or waterproof an item. We tried some techniques to glaze our 3d-printed, slipcast and compressed components, and we integrated a proposal for the glazed components with a further development of our design language: graded porosity. Finally, we studied ways to characterize and animate the external surfaces of our bricks.
138
6. GLAZE TEST AND DESIGN DEVELOPMENT 6.1 Glaze test 6.2 Design development 6.3 Glaze proposal 6.4 Language applications 6.5 Texture design
AD RC6 Material Consequences | UCL 139
6.1 GLAZE TEST
Glaze Procedures
One of the most traditional and characteristic processes of clay is glazing. This is a particular process which gives clay objects, already fired, a vitreous and colorful coat that makes the clay totally non porous. We carried out different glaze tests, in order to understand the behaviour of the material after the glazing procedure and the new firing, in terms of absorbancy of the colour and the final hardness and resistence of the clay body.
The procedure of glazing
140
1.Mix different glazing
2. Filter the glazing
3. Painting the bricks
4. Wait after drying
AD RC6 Material Consequences | UCL 141
6.1 GLAZE TEST After Firing
EB16-Mid Blue
Coral Pink
EB12-Blue Gray
EB17-Gray
Time for firing
1 hour
3 hours
3 hours
3 hours
Propotion
Pre-determined
3% Coral Pink
Colour
142
Pre-determined
Pre-determined
AD RC6 Material Consequences | UCL 143
6.1 GLAZE TEST After Firing
SLIP CASTING COMPONENT Eveness of the glaze Shrinkdge
144
3D PRINTING COM Eveness of the glaze Shrinkdge
MPONENT
COMPRESSION COMPONENT Eveness of the glaze Shrinkdge
AD RC6 Material Consequences | UCL 145
6.2 DESIGN DEVELOPMENT
Graded porosity: cross-scale components
The study in millipide of the behaviour of the basic square grid shows the weakness of it in the cantilever areas, where the components will fall down without the support of reinforcement bars.
146
AD RC6 Material Consequences | UCL 147
6.3 GLAZE PROPOSAL The cross-scale design research shows how it is possible to change the dimension of the modules and so the components. In the render beside it is clear how the size of the small modules is reduced proportionally. In fact, it represents 1/4 of the original size of the module. Since the parts of the wall that surround the openings are not particularly stressed the could easily be replaced with smaller modules in order to create variations and different interest in the overal design.
148
AD RC6 Material Consequences | UCL 149
2.4 LANGUAGE 2.3 6.4 ARCHITECTURE GLAZE PROPOSAL APPLICATIONS APPLICATION Cross-scale components
150
AD RC6 Material Consequences | UCL 151
6.5 TEXTURE DESIGN
152
AD RC6 Material Consequences | UCL 153
6.5 TEXTURE DESIGN
Design of different textures
154
AD RC6 Material Consequences | UCL 155
In order to make the wall feasible in the real architectural context, we analysed and tried to offer solutions to different issues deriving from the assembly logic, the stability of the joints and the variability of the components based on various factors, such as rotation, pattern and joints themselves.
156
7. PRELIMINARY FABRICATION STUDIES 7.1 Module optimization 7.2 Joints research 7.3 Frame design for assembly 7.4 Multiple variations of one component 7.5 The smart mould
AD RC6 Material Consequences | UCL 157
7.1 MODULE OPTIMIZATION
The weakness of the 4 components-module
COMPONENT A
COMPONENT B
158
4 COMPONENTS MODULE
EXAMPLES OF COMBINATIONS
AD RC6 Material Consequences | UCL 159
7.1 MODULE OPTIMIZATION The new module
1 COMPONENT MODULE
PATTERN VARIATIONS
160
EXAMPLES OF COMBINATIONS
AD RC6 Material Consequences | UCL 161
7.2 JOINTS RESEARCH Wooden pegs
In order to make the connections between the bricks stronger we decided to study and introduce an interlocking system, possibly made of wooden pegs, which would help both to stick the bricks together and to align them more accurately.
162
INTERLOCKING SYSTEM
Wooden pegs into the bricks in order to guarantee stronger and accurate connections
AD RC6 Material Consequences | UCL 163
7.2 JOINTS RESEARCH
Constraints on assembly
DIRECTION OF ASSEMBLY WOODEN PEG BLOCKING ASSEMBLY
164
AD RC6 Material Consequences | UCL 165
7.2 JOINTS RESEARCH Proposal
Due to the costraints on assembly analised before, we had to design a different interlocking system which would let each brick slide on the one on its side and fix it on the brick underneath. For this reason, we designed two different types of joints: A for the sliding system and B for the fixed system.
166
JOINT A Sliding system
JOINT B Fixed system
AD RC6 Material Consequences | UCL 167
7.2 JOINTS RESEARCH
The initial solutions Wooden pegs
JOINT A: Sliding system 6 mm
Metal sliding system
Bricks
50 mm 25 mm
Sliding system Wooden peg 106 mm
Wooden peg divided into two halves to fit into the bricks’ holes in order to allow a metal sliding joint, fixed on them through screws.
JOINT B: Fixed system 6 mm 50 mm 25 mm
Wooden peg
Fixed wooden peg 106 mm
168
Bricks
JOINT A: Nylon nut and bolt system Bolt
5 mm
Nylon nut Nylon washer
Bricks
50 mm 18 mm 10 mm
Washer and nut
Nylon bolt
105 mm
Joint realised with nylon bolt and nut sytem.
JOINT B: Nylon nut and bolt system 5 mm
Bricks
Nylon bolt
Washer and nut
18 mm 10 mm
50 mm
Bolt
Joint realised with nylon bolt and nut sytem.
105 mm
Nylon washer Nylon nut
AD RC6 Material Consequences | UCL 169
7.2 JOINTS RESEARCH Solution 3
JOINT A: Sliding system
50 mm 20 mm
5 mm
20 mm 50 mm
50 mm 20 mm
JOINT B: Fixed sy
170
35 mm
Bricks Wooden peg Fixed wooden peg
ystem 5 mm
Bricks Wooden peg
Fixed wooden peg
50 mm
AD RC6 Material Consequences | UCL 171
7.3 FRAME DESIGN FOR ASSEMBLY
Clay components and metal frame
Components quantity Components module
105
Base module
10
Total
115
320 cm
200 cm
172
AD RC6 Material Consequences | UCL 173
7.3 FRAME DESIGN FOR ASSEMBLY
Components quantity
Clay components and metal frame
Components module Base module Total
105 10 115
320 cm
200 cm
174
AD RC6 Material Consequences | UCL 175
7.3 FRAME DESIGN FOR ASSEMBLY
The connection between the joints and the metal frame
Solution 1: Sliding metal system with wooden pegs
176
Solution 2: Nylon bolts and nuts
Steel T-profiles connected to wooden pegs or the nylon joints
AD RC6 Material Consequences | UCL 177
7.4 MULTIPLE VARIATIONS OF ONE COMPONENT
DIFFERENT ROTATIONS
DIFFERENT PATTERNS
DIFFERENT HOLES FOR THE JOINTS
178
AD RC6 Material Consequences | UCL 179
7.4 MULTIPLE VARIATIONS OF ONE COMPONENT
The implications of the variations in a prototype wall
In order to understand and plan accurately the fabrication process, we designed and analised a wall as a prototype for our design proposal. From this type of analysis we could understand exactly how many bricks we need to fabricate and the differences and peculiarities of all bricks. We figured out the exact number of bricks we need to produce for each geometry and all variations we need to apply to the bricks depending on their rotation and on the position of the holes for the joints.
NUMBER OF BRICKS
180
BRICKS MODULE
106
BASE MODULE
10
TOTAL
115
NUMBER OF VARIATIONS
51
AD RC6 Material Consequences | UCL 181
7.5 THE SMART MOULD
Since the variability of the bricks is substantial because of the 6 different rotations of the bricks in the wall and the different positions and shapes of the holes for the joints, we would need to produce over 60 different moulds. Instead, we designed a smart mould system which consists in an unchangeable internal part and changeable and flexible external pieces. The external pieces of the mould are the ones which allow us to create the holes in the bricks or to apply on the external surfaces pattern. Through the smart mould system it is possible to have infinite different combinations of the smart pieces in order to produce all the variable bricks we have in the wall. Therefore, with a smart modular system we can still guarantee the unicity of our components.
TOT. PLASTER PIECES
21
TOT. INSIDE PIECES
15
TOT. SMART PIECES
6
Inside fixed pieces
Brick
External smart pieces
182
SMART PIECES FOR Y SHAPE
SMART PIECES FOR I SHAPE
SMART PIECES FOR T SHAPE AD RC6 Material Consequences | UCL 183
Based on the analyses and the solutions we designed to respond to technical issues, we carried out the new stage of the material research, characterised by the usage of new types of mould, and different fabrication procedures.
184
8. MATERIAL RESEARCH DEVELOPMENT 8.1 Fabrication procedures 8.2 Keys study for the mould 8.3 The mould of the mould 8.4 Plaster mould inside pieces 8.5 From high density foam to silicone 8.6 Comparation between the previous production system and the new one
AD RC6 Material Consequences | UCL 185
8.1 FABRICATION PROCEDURES
CNC
INTERLOCKING KEY TEST
1 WEEK
3DAYS
3DAYS
ONE WEEK
FIRING
186
DRYING
MOULD MAKING (SILICONE)
MOULD MAKING (PLASTER)
3DAYS
3DAYS
3 DAYS
10 DAYS/2 WEEKS
SLIP CASTING
MOULD DRYING
AD RC6 Material Consequences | UCL 187
8.2 KEYS STUDY FOR THE MOULD The high density foam keys
Key type 1. X
Key type 2. X
Key type 6. X
Key type 3. X
Key type 7.
Key type 4.
188
Key type 5. X
Key type 8.
Key type 9.
Slide key type 1.
Slide key type 2.
45°key type 1. X
45°key type 4. X
45°key type 2. X
45°key type 5.
45°key type 3. X
45°key type 6.
AD RC6 Material Consequences | UCL 189
8.2 KEYS STUDY FOR THE MOULD The plaster keys
190
Key type 4.
Key type 8.
Key type 7.
Key type 9.
Slide key type 1.
Slide key type 2.
45°key type 5.
45°key type 6.
AD RC6 Material Consequences | UCL 191
8.3 THE MOULD OF THE MOULD
The smart mould system for the high density foam moulds of the plaster mould
Each plaster pieces of the smart mould is fabricated by pouring liquid plaster into a negative mould made of high density foam, in order to guarantee accuracy. For this reason we had to design a new negative mould for each component of the plaster mould. But, since the high number of pieces constituting the plaster mould we needed to optimise the the fabrication and usage of the high density foam moulds. In fact, we studied a system that allowed us to use the same high density foam mould to produce at least two simmetrical plaster pieces. Concerning the smart plaster pieces we designed only one high density foam mould to realise all the variations of the smart pieces simply changing only one piece of the high density foam mould.
TOT. PLASTER PIECES
21
TOT. HDF MOULDS
10
MOULD A
MOULD D
MOULD H
192
MOULD B1
MOULD E
MOULD B2
MOULD F
MOULD C
MOULD G
High density foam mould Plaster mould
Plaster mould
MOULD I
MOULD J
AD RC6 Material Consequences | UCL 193
8.4 PLASTER MOULD INSIDE PIECES
All high density foam moulds to fabricate the plaster mould
Since we divided the mould into internal pieces and smart pieces(outside pieces), all the internal pieces are made by the high density foam. The procedure is to CNC the high density mould first, then cast plaster inside to get the plaster pieces.
MOULD J
MOULD E
194
MOULD F
MOULD I
MOULD G
MOULD H
MOULD A
AD RC6 Material Consequences | UCL 195
8.4 PLASTER MOULD PIECES
The fabrication process of each plaster piece from the high density foam mould
MOULD H
196
PLASTER PIECE H CASTING PROCEDURE
AD RC6 Material Consequences | UCL 197
8.4 PLASTER MOULD PIECES
Samples of pieces of the plaster moulds
198
AD RC6 Material Consequences | UCL 199
8.5 FROM HIGH DENSITY FOAM TO SILICONE
The fabrication process of silicone moulds for the components with holes
HIGH DENSITY FOAM
Costraints on casting plaster in high density foam
FLEXIBILITY
200
SILICONE
Flexibility of casting plaster in silicone moulds
FLEXIBILITY
AD RC6 Material Consequences | UCL 201
8.5 FROM HIGH DENSITY FOAM TO SILICONE
The processes of casting plaster in high density foam and silicone STEP 1
Step 1. Use high density foam to cast silicone
High density foam
202
Silicone
STEP 2
Step 2. use high density foam to cast plaster pieces
Silicone
Plaster mould
AD RC6 Material Consequences | UCL 203
8.5 FROM HIGH DENSITY FOAM TO SILICONE
The negative in silicone and the positive in plaster
Silicone moulds
204
Plaster pieces
Silicone moulds
Plaster pieces
AD RC6 Material Consequences | UCL 205
8.6 COMPARATION BETWEEN THE PREVIOUS PRODUCTION SYSTEM AND THE NEW ONE The advantages of the smart mould system compared to the previous one
Previous mould: HANDCRAFT AND SINGULAR OUTCOME
206
New mould: AUTOMATED AND MASS PRODUCTION
AD RC6 Material Consequences | UCL 207
After the new material tests and the results achieved with the new moulds and new fabrication techniques, we tried to gain mass production of our clay components. In order to do that, we developed different strategies, such as the smart mould, which could allow us to guarantee the fabrication of many components in a short period of time and to control the correctness of all pieces.
208
9. MASS PRODUCTION
9.1 Smart pieces 9.2 Mass production strategies 9.3 Fabrication procedures 9.4 Strategies for assembly
AD RC6 Material Consequences | UCL 209
9.1 SMART PIECES
The smart mould is based on the concept of dividing the plaster mould in inner pieces, which never change, annd outside pieces, the smart pieces, which allow us to characterize differently the external surfaces of the components. In fact, depending on the roations, the joints and the pattern, each component is different and unique, and simply by interchanging the external smart pieces it is possible to guarantee mass production and, at the same time unicity, without fabricating more than 50 different moulds, usable only once.
Smart pieces for the Y shape
6
Smart pieces for the I shape
13
Smart pieces for the T shape
7
C1 - C2
B1
C3
B2
B3
B
C D B
B
D
C
210
D1
D6
D2
D7
B4
7
C5
C4
B5
B6
B7
D3
B8
B9
C6
B10
B11
B12
B13
D5
D8-9 AD RC6 Material Consequences | UCL 211
9.1 SMART PIECES
Some samples of the plaster smart pieces
D1
212
D8
D1
D7
D6
D2
D3
B10
B3
B8
B4
C6
C1
C4
C3
B5
B6
B9
B7
AD RC6 Material Consequences | UCL 213
9.2 MASS PRODUCTION STRATEGIES Analysis of all variations in the wall TYPE OF ROTATION face 1
face 2
front face
COMBINATION OF SMART PIECES
FRONT PIECE
NUMBER OF SIMILAR COMPONENTS
a
D1 - B1 - D6 - B4
C1
2
D1 - B5 - D6 - B4
C1
1
c
D7 - B1 - D6 - B3
C1
6
.....
.................
.......
......
.....
.................
.......
......
i
D1 - B1 - D6 - B8
C1
1
b A
face 4
TYPE OF COMBINATION OF SMART PIECES
face 3
1 - 2 - 3 - 4
26
a
D6 - B4 - D6 - B9
C2
1
D6 - B10 - D1 - B2
C1
2
c
D6 - B10 - D6 - B2
C2
4
.....
.................
.......
......
.....
.................
.......
......
i
D6 - B4 - D1 - B2
C1
2
b B
19
a
B1 - D6 - B13 - D7
C1
1
B1 - D6 - B11 - D3
C2
2
c
B5 - D1 - B10 - D3
C1
2
.....
.................
.......
......
.....
.................
.......
......
h
B1 - D7 - B10 - D3
C1
1
b C
11
a
b D
c
d e f
B10 - D6 - B1 - D2
C1
4
B10 - D6 - B1 - D1
C2
2
B11 - D6 - B7 - D2
C1
1
B11 - D6 - B1 - D2
C1
1
B10 - D6 - B1 - D7
C1
1
B4 - D1 - B1 - D2
C1
1 10
214
TYPE OF ROTATION
TYPE OF COMBINATION OF SMART PIECES
COMBINATION OF SMART PIECES
FRONT PIECE
NUMBER OF SIMILAR COMPONENTS
a
C2 - D6 - C4 - D1
B7-1
1
C4 - D6 - C4 - D1
B7-3
2
C4 - D6 - C4 - D5
B7-2
6
C4 - D6 - C2 - D5
B7-1
1
C2 - D6 - C4 - D5
B7-2
1
C4 - D1 - C2 - D5
B7-1
1
b E
c
d e f
1 - 2 - 3 - 4
12
a
F
b c
D6 - C2 - D6 - C3
B7-1
1
D6 - C4 - D6 - C3
B7-2
9
D6 - C2 - D1 - C3
B7-1
3 13
G
a
b
C5 - B10 - C5 - B6
D9
2
C5 - B4 - C5 - B6
D8
1 3
H
a
b c
C6 - B1 - C5 - B4
D8
2
C6 - B1 - C5 - B12
D8
2
C5 - B1 - C5 - B12
D9
2 6
I
a
b
B10 - C5 - B7 - C5
D9
1
B10 - C5 - B6 - C5
D9
3 4
J
a
b
B5 - C5 - B12 - C5
D9
1
B1 - C5 - B12 - C5
D8
1 2
AD RC6 Material Consequences | UCL 215
9.2 MASS PRODUCTION STRATEGIES
Strategy for mass production with 5 moulds working at the same time
MOULD 2
MOULD 1
Rotation Type of combination
Num. A, B, C, D A-d A-a A-f A-h B-d C-b C-e A-b A-e A-i B-a B-f
Total number to fabricate Side smart pieces Front smart pieces
216
MOULD 3 Num.
A, B, C, D 9 2 1 2 5 2 2 1 1 1 1 1
A-c A-g B-g B-h C-a C-d C-f C-g C-h D-c D-d D-e D-f
28
MOULD 4 Num.
A, B, C, D 6 3 1 1 1 1 1 1 1 1 1 1 1
B-c D-a D-b B-b B-e B-i C-c
20
E, F 4 4 2 2 2 2 2
F-b E-c F-c E-a E-b E-d E-e E-f F-a
18
D1, D3, D6 B1, B2, B3, B4, B5, B7, B8, B9, B10, B11
D1, D2, D3, D6, D7 B1, B2, B3, B4, B7, B9, B10, B11
D1, D2, D3, D6, B1, B2, B4, B5, B10
D1, D5, D6, C2, C3, C4
C1 - C2
C1 - C2
C1 - C2
B4 - B7
MOULD 5 Num.
Num. G, H, I, J
9 6 3 1 2 1 1 1 1
G-a I-b I-a H-c J-b H-b H-a G-b J-a
25
2 3 1 2 1 2 2 1 1
15 B1, B4, B5, B6, B7, B10, B12, C5, C6 D8 - D9
AD RC6 Material Consequences | UCL 217
9.3 FABRICATION PROCEDURES Mould-assembly
During the assembly process, we place the plaster mould pieces in order, each of them will be locked by the special keys. When all the pieces are set in position, the empty space in the mould will be the same as the component.
The procedure of glazing
218
1.Mix different glazing
2. Filter the glazing
3. Painting the bricks
AD RC6 Material Consequences | UCL 219
9.3 FABRICATION PROCEDURES Mould-disassembling
After slip casting, we leave 5 hours for the plaster mould to absorb water from the slip. Then we disassemble the mould in order. The shape of the component is designed to be the nrgative of the mould.
The procedure of glazing
220
AD RC6 Material Consequences | UCL 221
9.3 FABRICATION PROCEDURES
5 moulds working at the same time
222
AD RC6 Material Consequences | UCL 223
9.3 FABRICATION PROCEDURES Drying and firing
224
AD RC6 Material Consequences | UCL 225
9.4 STRATEGIES FOR ASSEMBLY
Organization of assembly of unique components
Because of the unicity of each component, depending on the different rotations, patterns and joints and also on the type of “neighbour� component, we needed to guarantee an efficient strategy for the assembly, to collocate each component exactly in their position. For this reason, we assigned a specific number to each component in the design of the wall and marked each physical component with the corresponding number.
226
NUMBER IN THE WALL
ROTATION
COMBINATION
1
H
C6 - B1 - C5 - B4
D8
.....
.....
..................
......
2
A
D1 - B1 - D6 - B4
C1
.....
.....
..................
......
3
A
D1 - B5 - D6 - B4
C1
46
D
B10 - D6 - B1 - D2
C2
4
E
C2 - D6 - C4 - D1
B7-1
47
A
D7 - B1 - D6 - B3
C2
5
A
D1 - B1 - D6 - B4
C1
48
A
D6 - B1 - D7 - B3
C2
6
H
C6 - B1 - C5 - B4
D8
49
E
C4 - D6 - C4 - D5
B7-1
7
A
D7 - B1 - D6 - B3
C2
50
D
B11 - D6 - B7 - D2
C1
8
A
D6 - B1 - D6 - B3
C2
51
G
C5 - B4 - C5 - B6
D8
9
J
B5 - C5 - B12 - C5
D9
52
B
D6 - B10 - D6 - B7
C1
10
D
B10 - D6 - B1 - D2
C1
53
B
D1 - B10 - D6 - B2
C2
11
A
D6 - B5 - D6 - B3
C2
54
A
D6 - B1 - D6 - B3
C1
12
A
D7 - B1 - D6 - B3
C1
55
C
B1 - D6 - B10 - D3
C2
13
A
D6 - B7 - D6 - B3
C1
56
C
B7 - D6 - B10 - D3
C1
14
I
B10 - C5 - B7 - C5
D9
57
D
B10 - D6 - B1 - D1
C2
15
A
D6 - B1 - D6 - B3
C2
58
G
C5 - B10 - C5 - B6
D9
16
B
D6 - B4 - D6 - B9
C2
59
E
C4 - D6 - C4 - D5
B7-3
17
B
D6 - B10 - D1 - B2
C1
60
E
C4 - D6 - C4 - D1
B7-2
18
B
D1 - B10 - D6 - B2
C1
61
C
B7 - D6 - B10 - D3
C1
19
.....
.................
......
.....
.....
..................
......
20
.....
.................
......
.....
.....
..................
......
1 - 2 - 3 - 4
FRONT PIECE
NUMBER IN THE WALL
ROTATION
COMBINATION 1 - 2 - 3 - 4
FRONT PIECE
AD RC6 Material Consequences | UCL 227
9.4 STRATEGIES FOR ASSEMBLY
Samples of unique components with their distinctive number
228
88
21
60
33
32
35
44
27
48
30
34
4
44
68
81
67
63
58
AD RC6 Material Consequences | UCL 229
230
AD RC6 Material Consequences | UCL 231
The design of the proposal for the B-Pro Show consists in a 3d wall made of 106 clay components which, rotating and varying all the time, give dinamicity and a fascinating porosity configuration.
232
10. B-PRO SHOW PROPOSAL 10.1 Proposal 10.2 Strategy for installation 10.3 Compression tests 10.4 Assembly
AD RC6 Material Consequences | UCL 233
10.1 PROPOSAL
234
AD RC6 Material Consequences | UCL 235
10.2 STRATEGY FOR INSTALLATION
Analysis of the wall and the supporting structure
In order to guarantee stability and safety during the exhibition of B-Pro show we designed a structure, made of wood, at the base, and metal as further support behind and for the two sides of the wall. The wooden base at the bottom, made of 10 triangular units, is meaningful for the stability of the wall because of the 45 degrees grid that the position of the compontents follows. The metal structure behind is connected to the wooden base and through pegs placed in the components avoid that the wall bends forward.
N. Slip-cast components 106
Dimensions mm 2140x3200x225
Wooden base
1
1100x3270x300
Metal frame
1
2150x2820x45
Metal frame
Slip-cast components
Wooden pegs and metal rods
Wooden triangular base
236
DETAIL OF THE WOODEN PEG PLACED IN THE CLAY COMPONENTS, WITH THE METAL ROD FIXED IN IT
DETAIL OF THE JOINT BETWEEN THE RODS AND THE METAL FRAME
AD RC6 Material Consequences | UCL 237
10.3 COMPRESSION TESTS ROTATION 1
300 kg
NO CRASH TEST MAX.AVAI.LOAD
kg
200
FAILURE THRESHO.
kg
1.05
FAILURE DETECTION
%
5
FAILURE THRESHO.
kg
300
FAILURE DETECTION
%
500
200
0
500 s
1100 kg
CRASH TEST MAX.AVAI.LOAD
kg
437
FAILURE THRESHO.
kg
1.05
FAILURE DETECTION
%
15
FAILURE THRESHO.
kg
1100
FAILURE DETECTION
%
1100
437.34
0
1100 s MAXIMUM 437.34 KG
238
COMPRESSION TEST A Conclusion: The maximum load which can beapplied to the T-profile is 437.34 kg, So the component fulfill the performance of structural slip.
AD RC6 Material Consequences | UCL 239
10.3 COMPRESSION TESTS ROTATION 2
NO CRASH TEST
400 kg
MAX.AVAI.LOAD
kg
200
FAILURE THRESHO.
kg
1.05
FAILURE DETECTION
%
15
FAILURE THRESHO.
kg
400
FAILURE DETECTION
%
500
200
0
500 s
400 kg
CRASH TEST MAX.AVAI.LOAD
kg
231.89
FAILURE THRESHO.
kg
1.05
FAILURE DETECTION
%
15
FAILURE THRESHO.
kg
400
FAILURE DETECTION
%
500
231.89
0
500 s
MAXIMUM 231.89 KG
240
COMPRESSION TEST B Conclusion: The maximum load which can beapplied to the I-profile is 231.89 kg, So the component fulfill the performance of structural slip.
AD RC6 Material Consequences | UCL 241
10.4 ASSEMBLY
Assembly of the joints
The test of connection between wooden peg and metal frame
242
The test of the metal frame
AD RC6 Material Consequences | UCL 243
10.4 ASSEMBLY
Preparation of the wooden base
CNC the triangular wooden boards
244
CNC the triangular wooden boards
AD RC6 Material Consequences | UCL 245
In order to test the assembly procedures of the entire wall (designed for the B-Pro Show) we assembled a smaller prototype, understanding better how the components work in relation to each other and how the whole physical object interact with the surrounding environment.
246
11. PHYSICAL PROTOTYPE
11.1 Installation 11.2 Interaction with environment
AD RC6 Material Consequences | UCL 247
11.1 INSTALLATION
1
248
Main step of the assembling process is the placement of the wooden pegs inside the holes of the clay components, prearranged already at the fabrication stage. The wooden pegs proved to fit perfectly the holes and to interlock the components efficiently. The components matches well with the wooden pegs. The bricks are proved to be accurate enough for construction.
2
MOULD ASSEMBLY 1. The components are interlocked with each other 2&3. The detail and assembly of wooden peg connections.
3
AD RC6 Material Consequences | UCL 249
11.1 INSTALLATION
We started to assemble the components follow the diamond grid, lay bricks on the base and then place the wooden pegs in the joints. The pegs are used to lock the components in the next layer and prevents the components from moving.
250
AD RC6 Material Consequences | UCL 251
11.2 INTERACTION WITH ENVIRONMENT
252
AD RC6 Material Consequences | UCL 253
11.2 INTERACTION WITH ENVIRONMENT The photo aside shows a fascinating relation and perfect harmony between subjects represented: a traditional clay facade, an innovative and structural clay wall and nature. They are all natural elements which can inherently generate a dialogue between each other, emphasing the greater equilibrium characterising all natural systems. Furthermore, the picture suggests an interesting comparison between the old and the new, the tradition and the innovation. The common clay cladding of the building in the background and the innovative clay architectural language offered by the installation in foreground together communicate an important message. Clay is the oldest natural architectural material which have provided efficient technological solutions throughout the centuries but, still, can be further developed showing its potential for cutting-edge architectural languages.
254
AD RC6 Material Consequences | UCL 255
11.2 INTERACTION WITH ENVIRONMENT
The two pictures show and emphisize the main characteristic of the designed architectural language: porosity. The sunlight flowing through the porous components creates variable dynamic effects of light and shade projected on the surrounding elements and on the components themselves.
256
AD RC6 Material Consequences | UCL 257
11.2 INTERACTION WITH ENVIRONMENT
The relationship of the clay wall with the human presence and the effect of the sunlight coming through it and projecting on the floor.
258
AD RC6 Material Consequences | UCL 259
11.2 INTERACTION WITH ENVIRONMENT
A comparison between a night view with artificial light illuminating the clay wall and emphasizing the geometry and the porous components themselves and a day view, where the sunlight flows through the clay components and project variable effect of light and shade on the surrounding materials.
260
AD RC6 Material Consequences | UCL 261
In the final proposal we want to profit by all the previous studies and considerations. Thus, according to the material tests, we show possible feasible architectural applications of our design proposal together with the analysis of how we control the privacy, temperature, wind circulation by our generative porosity language.
262
12. FINAL PROPOSAL
12.1 The optimization of porosity 12.2 The solid brick 12.2.1. The effects on the inside microclimate 12.2.2. Architectural proposal
12.3 The hollow brick 12.3.1. The effects on shading 12.3.2. The supporting metal frame 12.3.3. Architectural proposal
AD RC6 Material Consequences | UCL 263
12.1 THE OPTIMIZATION OF THE POROSITY
privacy
264
public
privacy
public
privacy
AD RC6 Material Consequences | UCL 265
12.1 THE OPTIMIZATION OF THE POROSITY
266
Shading system and privacy We can control the privacy of the interior space by controlling the size of the holes on the porous wall. The wall act like a filter to make the interior space comfortable with mild temperature.
AD RC6 Material Consequences | UCL 267
In the final proposal we want to profit by all the previous studies and considerations. Thus, according to the material tests, Finally we show possible duable architectural applications of our design proposal together with the analysis of how we control the privacy, temperature, wind circulation by our generative porosity language.
268
12.2 THE SOLID BRICK
12.2.1. The effects on the inside microclimate 12.2.2. Architectural proposal
AD RC6 Material Consequences | UCL 269
12.2 ARCHITECTURAL PROPOSAL
270
AD RC6 Material Consequences | UCL 271
12.2.1. THE EFFECTS ON THE INSIDE MICROCLIMATE Windflow and temperature Velocity(m/s) 3.167 2.742 2.239 1.583 0
Normal wall
272
Normal wall with windows
Porous wall with modular components
Porous wall with cross-scale components
AD RC6 Material Consequences | UCL 273
12.2.1. THE EFFECTS ON THE INSIDE MICROCLIMATE Windflow and temperature Velocity(m/s) [ Pressure(Pa)] 19.599[ 103.413] 16.973[ 48.311] 13.859[ -6.791] 9.800[ -61.894] 0[ -116.996]
Normal wall
274
Normal wall with windows
Porous wall with modular components
Porous wall with cross-scale components AD RC6 Material Consequences | UCL 275
12.2.2. ARCHITECTURAL PROPOSAL
276
AD RC6 Material Consequences | UCL 277
12.2.2. ARCHITECTURAL PROPOSAL
278
AD RC6 Material Consequences | UCL 279
12.2.2. ARCHITECTURAL PROPOSAL
280
AD RC6 Material Consequences | UCL 281
In the final proposal we want to profit by all the previous studies and considerations. Thus, according to the material tests, Finally we show possible duable architectural applications of our design proposal together with the analysis of how we control the privacy, temperature, wind circulation by our generative porosity language.
282
12.3 THE HOLLOW BRICK 12.3.1. The effects on shading 12.3.2. The future application of slip-casting 12.3.3. Architectural proposal
AD RC6 Material Consequences | UCL 283
12.3 THE HOLLOW BRICK
284
AD RC6 Material Consequences | UCL 285
12.3.1 THE EFFECTS ON SHADING Radiation analysis kWh/m2
Radiation Analysis
193.49<
174.14
154.79 135.44 116.09 96.74 77.39 58.05 38.70 19.35
<0.00
Normal wall 286
Normal wall with windows
Porous wall with modular components
Porous wall with cross-scale components
AD RC6 Material Consequences | UCL 287
12.3.2. THE FUTURE APPLICATION OF SLIP CASTING The future application of slip casting components
Holburne Museum(Darwen terracotta)
288
Timber skyscraper(Researchers from Camb
bridge Universityâ&#x20AC;&#x2122;s Department of Architecture)
Central St. Giles London(Renzo Piano architect)
AD RC6 Material Consequences | UCL 289
12.3.3. ARCHITECTURAL PROPOSAL The sustainable skyscraper
290
AD RC6 Material Consequences | UCL 291
12.3.3. ARCHITECTURAL PROPOSAL The supporting metal frame
320 cm
200 cm
ASSEMBLY OF THE COMPONENTS
292
LAN
NGUAGE APPLICATION OF THE ARCHITECTURE SCREEN
CONNECTION WITH WOODEN PEGS
T PROFILE METAL FRAME
DETAIL DESIGN OF FRAME AND JOINTS
AD RC6 Material Consequences | UCL 293
12.3.3. ARCHITECTURAL PROPOSAL
294
AD RC6 Material Consequences | UCL 295
CONCLUSION AND FUTURE OUTLOOK The architectural research endeavoured to respond to those requirements with a sensible and realistic proposal. Learning from nature, the design investigation borrowed one of the most common and primordial characteristics, porosity, transposing it onto the architectural field This proposal is not meant to be the answer, the final solution and the end. It represents only the initial point of a new highly potential field of exploration. Unquestionably, many aspects should be further developed and optimised. However, starting from the knowledge and awareness acquired through this research, invaluable and crucial innovative solutions could be achieved.
296
AD RC6 Material Consequences | UCL 297