HydroMorphology Yasmina EL HELOU Thesis development at the Autodesk Technology Center - Boston, MA July to September 2019
The Autodesk Technology Center is an opportunity to develop a part of Hydro Morphology in a different background. It is a center that welcomes multiple teams of researchers and students. The Technology Centerhas valuable facilities making the research process more interesting and allowing projects to go further. After participating in the appropriate training, the residents are allowed to use the machine they need for their project; such as ABB robots, 3D printer machines, laser cutting machines, water jet machines, CNC milling machines, etc. For this phase of the project, during the two months of residency, the mold design for pouring concrete is the main target. The aim is to create molds that make the water absorption process more efficient. For that, the idea is to optimize the contact area between fog and tile by adding channels inside of the tile creating a way for the fog to circulate. The tile is now performative, not only on its surface but also inside. The images opposite show the first iterations of the concrete mold. They express the idea of large channelling systems inside the formwork. It is also clear that the mold is made out of a lattice, noncontinuous surface. This kind of structure allows the performance of the tile to persist even though the mold might be “trapped� inside of it. Indeed, the water droplets can still access the concrete regardless of the mold. Porous concrete being thick enough and having relatively big gravels will be poured perfectly without leaking from the mold.
First mold design
Different texture of the porous mold Porous concrete pooring Pores in the mold to optimize exchange surface Latice concrete mold
Different texture of the porous mold Section views
The diagrams above show a section of the formwork with different surfaces. They explain how the concrete and the mold are organized on the inside of the tile. The channels are empty and the water, fog, and wind can circulate freely inside the tile while it performs systematically. Different patterns are created to 3D print. The aim is to be able to print with the lowest amount of supports, to have the most effective circulation of water, and to print a reasonable scale for each purpose (visualization, exterior and interior coating, and actual use) of the mold. On the following images (next page) the first print is explained, the next ones will follow. The different copies show the printing tests. Some of them failed because of the small details and others because of the complex geometries requiring more supports for extrusion.
Working on the mold is interesting and shows different challenges, the first part focuses on the ability to have easy and effective geometries to produce. The process is done by dismantling the piece into little fragments and envision each part alone.
Complete formwork
Portion of formwork
Portion of a channel to 3D print
Portion of a channel - to print- divided i two peaces for a bigger, more detailed print
First 3D printing test, without supports
Part 1 - Smaller holes
Water movement Part 2 - Bogger holes : Better performance of the concrete, Facilitate intrusion of water droplets through the mold Comparing two prints of the same parts Porosity differences
Those pictures show different channels inside one tile. They are dismantled and printed separately for a better visualization process. Different iterations of the concrete tile are possible. The sections below show, the outside shell constituting the usual tile (previously designed), and in red the channels allowing the increase of the fog catching method.
Portions of the channels to 3D print
Wind Circulation
Empty channels allowing water and wind circulation inside the tile
Porous concrete Concrete mold
Sections of the formwork constituting one concrete tile
Sections of the formwork constituting one concrete tile
Not only is the design of the tile as a concept essential, but also the application of the design. To begin with, it is easier to simplify the process and fabricate a smaller concrete tile with only one channel. Later the porous concrete would be poured and the channel will create the wanted void in the tile. The first method presumed for this process is to create 3D printed channels, and cast thin foldable metal sheets in those channels. Finally, the metal sheets will take the form of the void predefined and will be fixed on wood formwork for the concrete. For now, there is no texture on the metal sheet, it is, therefore, removable from the concrete once it cures. This will surely allow the concrete to be performative since there will be no obstruction between it and the ambient foggy air. Flexible metal sheet
Compressing metal sheet on the 3D printed mold
Creating molds for metal sheets
Other ways are developed to cast the concrete and try to compare the best method for tiles and prototypes. Multiple materials can be used such as PLA (3D printed channel) and wood (for the mold sides). This way, it will be possible to test whether the concrete can be cast inside 3D printed molds and still be removed from the mold afterward (enable multiple uses of the same mold). Additionally, the channel can be placed in different positions for testing in the concrete tile.
The Autodesk technology center allowed this project to have a more detailed design approach. It was the opportunity to develop a better understanding and analyzing the concrete tile with more freedom and autonomy. The BuildSpace permits the residents to be comfortable with the tools they are using and to have a stable idea of the materials and technologies that could possibly be used for fabrication.
A sectioned tile is developed by milling half of a channel and pouring concrete onto the wood. This way, it will be easy to visualize the path of the channel and its effect on the porous concrete.
Wood box and metal channel
Concrete block Interior void
3D Printed channel Wooden mold walls
Concrete pouring
Porous concrete Wooden mold
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Some wooden molds 1 - 3D printed channel + Wood walls 2 - Half a tile
Concrete tile - Visualization of a section
Testing the channels on porous concrete tiles
Yasmina El Helou Iaac / Autodesk - 2019 -