2015 schindler etal interlocking

2 Christoph Schindler Martin Tamke Ali Tabatabai Martin Bereuter Hironori Yoshida

PROCESSING BRANCHES Reactivating the performativity of natural wooden form with contemporary information technology

Angled and forked wood – a valued material until the nineteenth century – was swept away by industrialisation and its standardisation of processes and materials. Contemporary information technology has the potential for capturing and recognising individual geometries through laser scanning and computation and subsequently design and bespoke CNC fabrication.

A series of workshops and projects exploring the performative potential of naturally grown materials discussed whether this technology allows for a new approach to the uniqueness that is offered to us by nature.

Introduction Until the nineteenth century, naturally grown wooden form was a desired material in the construction of ship bodies, almost entirely for Viking longships [1], carriages and sledges, but also in architectural contexts like Norwegian stave churches or Japanese roof constructions [2]. Having grown in an angled or forked form, these pieces demonstrate outstanding performance due to their internal fibre orientation. Hence they were sometimes even more costly than straight pieces. The dawn of industry and the accompanying standardisation of all processes and materials swept the highly performative but individual aside. All parts of a tree that opposed classification were henceforth considered as ‘wood defects’— although they are by no means defects in the system of a tree. In architecture, this distinction has persisted up to the present day, a time when trees are more likely to be used as ‘potent architectural symbol’ [3] than as structural elements.

Material Approach Over recent decades, architects have returned to a recognition that high performance comes through the ability to adapt to local conditions [4].

This is especially true for architecture and its related systems, as most buildings are unique objects. A computational understanding has permitted a general orientation towards non-standard approaches, and has developed in parallel with massive progress in the understanding of material composition as well as the introduction of digital design and fabrication processes that can handle the making of the bespoke.

Whereas machines of the industrial age are geared towards repetition and uniformity, techniques such as 3D scanning, parametric CAD software and digital fabrication allow us to work with individualised elements.

Can these approaches restore our access to the uniqueness offered by nature?

Into the woods

For our workshop, we chose to focus on beech wood. Firstly because hardwoods like beech have stronger branches than softwood, and secondly because the setting was Denmark, where beech is the most common hardwood forest tree (even mentioned in the Danish National Anthem). Before the workshop, participants collected branches in the forest of Nødebo Skovskolen following their own personal preferences and agendas. We collected without evaluating the branches’ structural/material quality, instead just looking individually at form potentials and visual appearance. We then categorised the collected branches within the workshop group. This step initiated discussion of the material variance process by registering the collected material through grouping and distinguishing their performative qualities, appearances and characteristics (uniqueness, 3D, 2D, Y-shape, different angles, curved, linear etc.). Following that, we assigned each branch to one of three major categories – variations on Y-shape, flatness (2D branches), and uniqueness (3D branches).

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Wood does not just grow in unique geometries; it comes with unique material properties as well. This is especially true for the branches – the focus of this chapter.

Branches could well become an up-to-theminute ecological material when combined with contemporary information technology.

Whereas the trunk of a tree receives weight mainly from above (vertical loads), branches sustain loads almost perpendicular to their main growth direction and structurally behave like cantilevers with a full-moment connection. In reaction to this load, softwood trees (conifers) develop reaction wood under compressive force at the lower side of the stem – called compression wood – while hardwood trees (angiosperms) develop reaction wood under tension at the upper side of the stem – known as tension wood. Forked wood can be regarded as a high-tensile and elastic joint of high intelligence. Whereas a crotch might seem to be a simple split, its growth pattern creates an interweavement of fibres that provides stiffness and elasticity in multiple planes. The crotch is naturally able to accommodate load from various directions.

contrast, using a different set of references, Barnett and Jeronimidis [6] conclude that ‘mechanically, at least, tension wood is a better wood than normal’, its value mainly limited by extensive shrinkage.

Our project was multidisciplinary, initiated by a furniture manufacturer in cooperation with a carpenter, and developed further during an 8-day workshop with 19 students of architecture at the Royal Academy of Fine Arts, Schools of Architecture, Design and Conversation (KADK). Our starting point was speculation about assembly techniques and resulting objects, based around the following questions For which kinds of objects can we use branches and assemblies of these?

How can we exploit the individual shapes of branches for particular purposes?

To what extent should we transform the branches?

We became especially interested in hardwood forks, as these split into two approximately equal parts. This seemed to us closer to architectural applications than the softwood with its dominant trunk.

Pre-studies showed that the variation in the angle of crotches stays in a limited range for each species of tree.

For instance, a broad selection of branches from beech showed differences in the forking angle of no more than 20°.

However, in recent wood science, there is disagreement regarding the usability of hardwood’s tension wood. Shmulsky and Jones [5] state that ‘strength of tension wood generally compares unfavourably with that of normal mature wood’ and note as qualities only its higher cellulose content and higher density, which ‘results in slightly improved chemical pulp yields’. In 31

Material Computation

How to compute branches

During the course of developing five different group projects, we identified two strategies to approach the branches.

The first approach is based on advances in capturing, representation and fabrication of materials through digital techniques.

The last decade has seen the emergence of a digital chain that links the design environment with fabrication.

The creation of interfaces between design and production makes it possible to activate the potential of traditional wooden joinery to face the challenges of contemporary timber architecture [7].

Current research is suggesting a ‘new material practice’ [8] that extends the geometric understanding of material with a fixed set of material constants into the recognition and use of material behaviour.

These approaches range from design with bending behaviour in active bending structures [9] to the use of materials to compute, for which Menges has coined the term ‘material computation’: In architecture, computation provides a powerful agency for both informing the design process through specific material behavior and characteristics, and in turn informing the organization of matter and material across multiple scales based on feedback with the environment. [10] These approaches rely inherently on the very detailed understanding and specification of the material behaviour of every element.

In our case, the knowledge we need about the material goes beyond the existing definitions of material properties that are found through empirical testing across a series of elements.

Branches have widely varying properties (in itself considered a ‘wood defect’). Their individuality and inhomogeneity collide with a digital workflow that takes as its point of departure the capturing of an element’s properties – which for branches are not given. To capture a branch requires not only a recording of its form with tools such as Microsoft Kinect (2010) or photogrammetric software, which are now increasingly common. There must also be non-destructive ways to formalise its specific physical, mechanical and chemical behaviours. First attempts to gain insight into the design potentials of these parameters hidden in the material include x-ray scanning of timber [11] and the subsequent simulation of its elements’ behaviour through a fine-grained simulation [12]. However, these approaches are still in their early stages, limited by the current high cost of the scientific equipment (which in case of the x-ray scanner can also be harmful).

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During our workshop, we focused on the capturing and subsequent processing of geometrical data derived from the crotches (Figure 1), with a view to treating them as a building element with a defined angle.

The registration of these angles allowed us to determine a place for each piece in an overall assembly with a given design intent. The assembly of crotches with matching angles could become a procedure

Within the workshop, we tested low-end approaches with a Microsoft Kinect scanner and subsequent approximation of the geometrical axis of the branches as well as detailed scanning using a Roland 3D laser scanner. The registration of branch geometry proves to be a substantial obstacle. Whereas the scanners could capture the geometry in a reliable way, the definition of axis lines – crucial for the application of joints – was difficult. As part of the ‘Prosthetic Branching’ project (Figure 2) we put the cart before the horse: a 3D scan of the crotches’ ends served as mould for the interior shape of a clamp encompassing the whole end of the branch.

Having a tight grip and perfect fit, this approach sets aside the idea of working specifically with the inhomogeneous crotch but works specifically for the crotch with a homogeneous material like Medium Density Fibreboard (MDF). This artificially fabricated element negotiates between the naturally grown ones.

Fig. 1 Registration and processing of branches at KADK using a fixed registration plate Fig. 2 ‘Prosthetic Branching’ created experimental joints whose function was to form the connecting pieces between a pair of branches. A detailed scan of the end of the crotches served as the negative for the interior shape of a clamp encompassing the whole end of the branch. The joint were milled in MDF on a 3-axis router.

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that follows statistical strategies similar to those applied to limestone leftover pieces in the ‘Smart Scrap’ project directed by Kevin Klinger at Ball State University [23].

The CNC fabrication of wooden joints would allow for connecting the selected elements

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Computational processing of wooden branching geometries At a workshop at the Chair of CAAD at ETH Zurich dedicated to the specific properties of the yew tree, E. Xexaki and Y. Ishizu with A. Xydis designed a pattern using tree cross-sections. The yew sections were cut and scanned. The task was made feasible by the fact that the scanned geometry consists only of an outline and a height (2½D). A circle-packing algorithm arranged the outlines to form an attractive ornament which served as layout for a shading pattern for an entrance door (Figure 5) [18].

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Computational capturing of wooden branching geometries In settings subsequent to the workshop we successfully worked with scanned grown wooden form by reducing its complexity: The workshop’s attempts to scan branches revealed that registration of branches is necessary in order to process them, and that an internal geometrical reference system is needed if one is to prepare them and design with them. The workshop used manual registration of these axis systems, which turned out to be laborious and prone to error. Recent developments in computer science suggest algorithmic approaches to identify tubular geometries in point clouds.

While the focus is mainly on the detection of pipes in industrial settings [13, 14, 15] some research is concerned with detection of individual trees [16]. Both directions inspired an approach which was used in a project at CITA to detect branches in large-scale point clouds (Figure 3) from laser scans in forests.

While aerial 3D scanning of forests is common today (and some forestry operations also use terrestrial 3D scanning for wooden mass estimation [17]), we took higher resolution scans as a base. This 34

identified individual scans of trees, and an algorithm detected the upward direction of the tree at a defined height above ground.

Exact outlines and area measurements of the tree in predefined steps were subsequently generated and referenced to each other. The algorithm detects the widening and branching of trees and inserts furcation into the axis representations (Figure 4).

Fig. 3 A 3D Point Cloud of a scanning campaign in Skåne, Sweden served as sample dataset for the project Fig. 4 The developed algorithm creates threedimensional axis representations of trees with attached information on diameter and shape of cross-sections

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Fig 5. An entrance door made of yew tree crosssections arranged with a circle-packing algorithm.

The door serves today as entrance door for the City of Zurich’s new forestry building at Albisgüetli 4

The generation of a vast number of axis representations of branches by forestry scans makes them a potential resource for design. In future design scenarios branches could be identified in forests that satisfy specified angle and diameter criteria. The same database can equally serve bottom up approaches, where structures are built from the natural resource available in a forest. Projects arising from the workshop, such as the ‘Interpretations of a Formal Grid Structure’ project (Figure 10), would have benefited greatly from a searchable dataset capable of identifying the best fitting branches for specific uses

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Material Variance While appraising the digital tools, we also had a close look at the traditional methods of processing naturally grown shape, as applied for instance to the construction of Viking longships or in Japanese joinery.

The geometry of the components was not defined numerically but transferred directly by drawing onto the wood, without first being captured in absolute measurements.

Benje writes: The further the formation of the workpiece moved forward, the more important the actual piece became in comparison to the plan. [19] The dimensional reference of a component was not an absolute number but rather the derivation of the hierarchically overlying or adjacent component. The dimensions were determined by deriving from one element to the next one, further and further. This is particularly evident in the wood joints.

Components that have been processed with hand tools only interlock mutually, and are not interchangeable. In case of frequently required geometries, jigs were applied for scribing, in which case the components relatively depended on the jig. In any case, the geometry of a wood compound is aligned relative to the respective adjacent component [20].

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In our workshop, we first observed the boat builders at the Viking Ship Museum Roskilde applying this technique, and then were able to confirm their theories by testing them on full-scale reconstructions (Figure 6). Later we experienced in our own projects that the geometry of grown wood could not be properly measured with our digital scanning devices; everything had to be continually adjusted with hand tools on-site (for instance ‘Prosthetic Branches’, Figure 2; ‘Triangulated Branches’, Figure 11). The ‘Interpretations of a Formal Grid Structure’ project (Figure 10) followed another approach: instead of modifying the branches, a joint with high tolerance was proposed. The ‘Optical Joints’ project (Figure 7) sidestepped the issue with an elegant artistic stratagem: The construction consists of a single branch that is reflected in various mirrors without any joint – an approach that cannot be materialised with branches, but must instead be visualised as a 3D model from a scanned branch and brought back to reality with a 3D printer.

At that point we wondered whether capturing as much data as possible was the only way of dealing with the branch geometry – what would be the result if we tried to limit the amount of necessary

information to the minimum? Consequently, we considered if there might be design approaches that take the natural variation into account by considering unusually high tolerances and defining as few measurements as possible. These questions led us directly to an unconventional fabrication strategy. Taking on an approach developed by carpenter Martin Bereuter for a competition entry at ‘Handwerk+Form’ in 2012, we made the branches plane on both sides with a mechanical planer that could measure the remaining material thickness with a precision of 0.1 mm. This process results in two parallel surfaces at a defined distance apart – all other measurements remaining unknown (Figure 8) The approach was tested in two studies.

With the ‘Branch Stool’, a CNC-milled seating surface comes with three grooves, into which planed branches of thickness are inserted (Figure 9) [21]. The ‘Triangulated Branches’ project follows the same approach: a planed branch is described by its material thickness and three points of an outline-triangle drawn around it (Figure 11, making it a triangular geometry. In both projects, the exact shape of the branch can be disregarded as long as it stays within a defined tolerance.

Fig. 6 The form of a jig for a Viking longship rib applied to a naturally grown fork Fig. 7 ‘Optical Joints’ investigated how naturally grown shapes could tessellate into structural repetitive patterns and closed shapes by experimenting with optically joining individual unique branches into serial mirrored repetitions. The process started with 3D scanning, and then further developed an experimental structure by mirroring with real mirrors as well as with 3D modelling software, finally materialising the serial branch with a 3D printer.

Fig. 8 Individual branches captured solely by the distance between two planed parallel surfaces.

In the context of the yew workshop at ETH mentioned above, the same approach was applied to the balustrade of the City of Zurich’s new forestry building at Albisgüetli (Figure 12). The yew elements are arranged in such a way that the distance required because of their individual growth nowhere exceeds the diameter of a child’s head, 12cm as stipulated by Swiss building safety regulations.

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Conclusions

Capture

Our research shows that the handling and fabrication of branches challenges our understanding of design and production processes. Exploration of the potential of digital tools can be hampered by thinking that is bound to the heritage of industrialization: We are used to working with measurable geometry, minimal tolerance and reliable material constraints.

Consequently, we faced unexpected obstacles in developing smooth digital chains from scanning to production (i.e. branches mismatching with customized joints). We had to question our convictions and use our tools in unconventional ways to establish avenues by which to approach the branches.

In our workshop, we made an attempt to capture the form of grown materials. It would have been even more demanding to feed a grown material’s behavioural properties into a parametric model, as required for a ‘material computation’ strategy – standardised material constraints such as can be looked up for derived timber products barely exist for grown material.

To understand a material’s properties, tools for non-destructive determination of mechanical and physical characteristics are required. While we can only speculate about potential links between x-ray scanning and estimation of behavioural properties, 2D and 3D scanners for the measurement of surface and volume have become accessible in a way that was beyond our imagination only a few years back. The success of the stool and the door is built upon a significant geometric simplification to 2D (or 2½D) cross-sections and length-sections of wooden elements.

But even with that constraint on geometry, we found our existing set of techniques and especially our industrial mind-set to be challenged.

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Fig. 9 The ‘Branch Stool’ consists of a CNC-milled seating surface with three grooves, into which planed branches of matching material thickness are inserted Fig. 10 ‘Interpretations of a Formal Grid Structure’ looks for the formal logic of natural branches with their organic shapes. This project explored what happens if you force the branches into behaving like a formal grid structure. The process was developed through mapping and capturing Y-shape branches in 2D and further working with them as outlined silhouettes to explore their potential as elements in grid based structures.

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Fig. 11 ‘Triangulated Branches’ explored the possibilities in using branches as elements in a triangulated polygonal surface through registering each Y-shaped branch by its bounding-box fitting in a triangle of the controlled polygonal surface. Each branch was further processed and flattened with two parallel surfaces to make it more convenient to work with using standard wood-shop machinery

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Scope of Applications The case studies that flowed from our workshop ranged from joint studies, construction systems and ergonomic studies to applicable pieces of furniture and secondary building elements like the door and the balustrade. They have not (as yet) extended to the realm of building scale. During the workshop we found it quite challenging to develop adequate applications for such branches. Functionality in particular remained beyond our reach, as most groups decided on an approach without a direct functional claim. However, if we look at highly functional traditional examples like the Viking longship, we predict that applications for naturally grown wood can go further. It would not be the first time that groundbreaking technologies are first applied to the improvement of established design concepts and construction logics [22].

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This text was edited from a previously published version in International Journal of Architectural Computing IJAC Vol 12 Nr. 2, Multi Science Publishing, Brentwood 2014, pp. 101–116

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