3
4
PIXELSTONE MICROSTRATA
FAME ORNRUJA BOONYASIT | MAHO AKITA | SYAZWAN RUSDI | WONIL SON BARTELETT SCHOOL OF ARCHITECTURE GRADUATE ARCHITECTURAL DESIGN RESEARCH CLUSTER 4 TUTOR :MANUEL JIMENEZ GARCIA, GILLES RETSIN
29,AUG, 2014
Contents Phase 0 INTRODUCTION
5p
0.1_ RESEARCH STRAND 0.2_ GOTHIC SUBSTANCE 0.3_ THE 3D PRINTING TECHNOLOGY 0.4_ GOTHIC PROSTHESIS 0.5_ MICROSTRATA
Phase 1 INITIAL FABRICATION
45p
1.1_ MATERIALS 1.2_ ROBOTIC FOR FABRICATION 1.3_ ROBOTIC TOOL PATH 1.4_ ADVANCED TOOL STRATEGY
Phase 2 TEST CASE: COLUMN
71p
2.1_ MICROSTRATA REINFORCED CONCRETE 2.2_ MICROSTRATA COLUMN ALGORITHM _V.I 2.3_ CAVITY COLUMNS 2.4_ MULTI-COLUMNS 2.5_ PRINTING COLUMN 2.6_ TOOL DESIGN
Phases 3 DIGITAL TENSION NETWORK 3.1_ TOPOLOGICAL OPTIMISATION 3.2_ VENATION SYSTEM_LAYER 3.3_ VENATION STRATA 3.4_ DIFFUSION LIMITED AGGREGATION 3.5_ DLA with TOPOLOGICAL OPTIMISATION 3.6_ COLUMN PROTOTYPE_DLA 3.7_ ARCHITECTURAL DLA SPACE 3.8_ FABRICATE DLA SPACE
97p
Phase 4 LINEAR FABRICATION
131p
4.1_ ARTICULATING TENSION NETWORK 4.2_ RECURSIVE TENSION NETWORK 4.3_ PRINTING CONTOUR DRAWING 4.4_ BOUNDARY OF PRINT RANGE 4.5_ CASTING ALTERNATIVE REBAR
Phase 5 BRANCHING SYSTEM
157p
Phase 6 PRINTING VOXEL
195p
5.1_ BRANCHING REINFORCEMENT BAR 5.2_ STRESS AND BRANCH 5.3_ VOXELIZATION 5.4_ SUBTRACTION 5.5_ ARCHITECTURAL SPACE
6 . 1 _ T R A N S I T I ON BE T WE E N L INE AR T O V OX E L MATR IX
6 . 2 _ M U L T I P L E N OZ Z L E T OOL IN M AT RIX
Phase 7 Metal Casting
215p
Phase 8 LINE _ PIXEL
227p
Phase 9 PIXELSTONE_FABRICATION
235p
Phase 10 PIXELSTONE
245p
Phase 11 ARCHITECTURAL SCALE PROJECTION
259p
APPENDIX
2 MI CR O ST R ATA RESEA RCH STRA N D
Structural Analysis
Gothic Substance
Multi-Objects Analysis
Computational
Gothic Prosthesis
Fabrication Research
Material Research
3 Voxelization - Pixelstone
Computational
1st Generation Tool 2nd Generation Tool 3rd Generation Tool
4th Generation Tool 5th Generation Tool
4
INTRODUCTION
5 INTRODUCTION
Phase 0 INTRODUCTION
6 INTRODUCTION
R C 4 : DE E P SU BSTAN C E Cluster 4 research agenda is greatly influenced by the Gothic architecture where elements such as structure, ornaments and spatial hierarchy blends together, blurring the line that define individual typology to be read as a single entity. The theme ‘Deep Substance’ signifies our interest in the fusion of multiobject artefacts that are structured in multi-layered narrative, composed into intelligent hierarchy and took high-resolution form. In this compact 1 year course, the strategy of Cluster 4 has been to develop a single project each term in which all inputs would accumulate and converged into a focused and more elaborated final thesis proposal. Learning from the gothic, we explores multi-object design that re-inform structural typology. Term 2 saw the continuation of the gothic spirit in generating feasible monolithic structure piece with micro articulation of materials and agent based algorithm. Ideas from these extensive research and experiments was structured towards fabrication logic that maintains close feedback between digital and physical realms.
7 The project investigates the dichotomy between additive manufacturing fabrication and generative design through computational methodologies. Reconciliation of these two realms as a single bottom-up process in architecture could initiate a paradigm shift in the way building industry works in the future particularly in reinforced concrete structure. The research objective is to establish a prototypical ‘reinforced concrete’ structure system by integrating digital and 3D printing tool. This design research encompases several phases of excercise and workshops that investigate the Gothic elements, structural analysis, computational tools, material research and the physical fabrication. The Gothic Substance Gothic ontology is being investigated to find the logic behind muntifigural, ornamental and structural elements. Structural Analysis An analysis based on structural performance of a gothic structure was done that leads to an excercise called 'Gothic Prosthesis' Computational Tools Structural data was gathered and scripted into computational logics and agent based behaviour to generate responsive structural element. Material Research Compression based material was selected and tested to generate the best compression structure based on digital fabrication method. Fabrication Robotic arm was used as a mediator between the digital and physical world in which, materialization of digital output is made possible.
INTRODUCTION
0.1_ RESEARC H STRAND
8
INTRODUCTION
9 INTRODUCTION 0.2_ GOTHIC SUBSTANC E Gothic Architecture has gained it's reputation by harmonizing ornamental features within the physical structures. This style has evolved through the years of practice by the builders. Each structural elements are being crafted as a work of art that transpires the whole composition of the building. The best part about the 'gothic attitude' is that almost every aspect of the 'art' has it's own important role in the structural integrity of the whole.
1
2
Gothic column design iterations
Unique rib vault of St. Hugh's Choir, 1192, rebuilt 1239. Lincoln Cathedral, Lincolnshire, England
10
0 . 3 _ T HE 3 D P RI N TI N G TECH N OLOGY
INTRODUCTION
3-D printing allows materialisation of virtual object with high precision and in a cost effective way. Since its conception over 30 years ago, several different technique has been developed including Fused Deposition Modelling (FDM), Selective Laser Melting (SLM), Selective Laser Sintering (SLS), Stereolithography (SLA) and a few others. The development of a more resilient methods run concurrently with deep understanding in engineering, physics and material science over time. All process shares similar goal in which to come up with a more efficient, cost effective and reliable fabrication method of the future. 3-D printing was originally developed for rapid prototyping purposes, making one or two physical samples. It allowed designers to identify and correct design flaws quickly and cheaply, thereby speeding up the product development process and minimizing commercial risks. According to business analysts CSC, prototyping remains the largest commercial application of the technology, accounting for some 70 percent of the 3-D print market. However, improvements in the technology’s accuracy and speed, as well as in the quality of materials used for printing, have prompted some commercial sectors to move beyond the use of 3-D printing in their research and development (R&D) labs and incorporate it into their manufacturing strategy. [1] The process of “growing� objects layer by layer also means that, with 3-D printing, it is possible to create more intricate and complex structures than can be done using traditional manufacturing techniques.
Voxeljet 3D printer
1
2 Voxeljet 3D Printer
11 Voxeljet ventures into large-format 3-D printing with the ability to command extremely high resolution sand printing up to 3 micron. Using patented resin composite binder formula, voxeljet able to bind each grain of sand together to materialize highly complex 3-d printed objects. Their technology is already been put to application in a very diverse fields including automotive, aviation, film and production, engineering, architecture and medical. The ability to fabricate high complexity geometric form opens up a new possibility for architects and designers to materialize their works. Michael Hansmeyer, a post-modernist architect take advantage of voxeljet's 3D-printing potential to fabricate his highly intricate computational designed works such as the Grotto and Subdivided Columns.
High Precision Metal Casting By using sand as printing material, voxeljet takes advantage of its inherent properties in metal casting system. For the first time, metal casting process could be done quick and efficient way in by digitally model and print the mould without the need of complex and expensive moulding equipment. Designer Peter Donders apply this process in his work, Batoidea chair; casted homogeneously in aluminum in five pieces.
3 Grotto, by Michael Hansmeyer 4
Batoidea Chair, by Peter Donders
INTRODUCTION
High-Resolution Digital Fabrication
12 INTRODUCTION Contour Crafting
1
13 D-Shape, invented by Enrico Dini is a large 3-Dimensional printer that uses stereolithography, a layer by layer printing process, to bind sand with an inorganic seawater and magnesium-based binder in order to create stone-like objects. The current version of the D-Shape 3-D printer sits in a 6m by 6m aluminum frame. The frame consists of a square base that moves upwards along four vertical beams during the printing process via stepper motors, which are used to repeatedly move a specified length and then hold in place, on each beam. Spanning the entire horizontal 6m of the base is a printer head with 300 nozzles, each spaced 20mm apart. The printer head is connected to the base by an aluminum beam that runs perpendicular to the printer head. [8] Sand as a construction material has already been in use in the industry. In individual research of bioMason by Ginger Krieg Dosier, sand yields a high potentiality in real architectural application. Howver, it still resides in the form of a brick. With promising technology available today, large scale 3D printing and the application of sand still heavily rely on compressive material in which the end product will only stand in compression. Much like all medieval construction, compression-only building solution comes with great limitation in flexibility of form.
1 Enrico Dini, D-shape
2
D-shape large scale printer
INTRODUCTION
3D-Printing in Architectural Scale
14
Reinforcement Intervention
INTRODUCTION
Although a wide variety of material has been used in 3D-printing, they all shares one common trait; they all only work in compression. This put a limit into the produced object to perform in tension. Like masonry and concrete construction, the only solution to surpass this problem is to have reinforcement embedded within the structure itself. Modern architecture solved this problem by the invention of reinforced concrete, in which metal reinforcement bars are layed within the concrete mass to perform in both tension and compression. This solution enables builders to design in a more robust and versatile way. However, despite of its robust quality, reinforced concrete construction proves to be highly unsustainable and consumes excessive amount of time and human labour considering the rebars' physical limitation. Heinz Isler's tension network following tension stress direction, is an optimum response to the constraint of the rebar. However, the execution requires long hours of work and high level of expertise in order to arrange material with precision.
Sagrada Familia construction, Antonio GaudĂ
1
Tennishalle, Heinz Isler
2
Tennishalle, Heinz Isler
3
Microstrata researches fabrication technique to create artificial sandstone with casted rebar, reinventing reinforced concrete. The computational logic of agent-based algorithm is employed in the creation of interconnected, fine networks of venation with high-resolution according to tension structural data. The idea of reinforced concrete is reinterpreted into metal casting technique which results in tension networks with structural performance adequate to that of conventional rebar. Compression blocks are fabricated by additive manufacturing method with high precision, leaving interconnected networks of cavities for tension material casting. MICROSTRATA investigate micro-organization system, turning sand into performative structures. Sand is an abundantly available substance with high potential for compressionbased construction. Considering the micro unit of a grain of sand, MICROSTRATA researches into an optimized method of architectural scale 3D printing in respond to material behaviour in the creation of high resolution structure. With the application of robot, MICROSTRATA algorithm directly transcoded the design as voxel output, generating micro layers of toolpath. From design to fabrication, the data flow does not dwell solely in the realm of virtuality, it is translated into material reality.
1
Pixelstone Project Code Microstrata
2
Pixelstone Project Prototype, Microstrata
3
Pixelstone Project Physical Prototype Microstrata
15 INTRODUCTION
MICROSTRATA Algorithm
17 GOTHIC PROTHESIS 0.4_ GOTHIC PROSTHES I S Gothic prosthesis is an exploration to determine how
With the Gothic attitude, the idea inherited in work-
structural physics plays an important role in the Goth-
shop I is hence adapted in real architectural scale,
ic design. Case was made by observing a prominent
with specific spatial identity and structural articula-
Gothic structure - the flying butress.
tion. In this realization, a flying buttress is replaced with the proposed prosthesis. Initial studies in the properties and elements which are the essence of the Gothic is the origin of the computational logic. An agent-based algorithm is created by applying multi-objects idea with structural formation logic which reacts according to structural data. Like that of the Gothic edifice, the novel structure is opulently composed of rich overlapping elements, resulting in a prosthesis which is at once structural and ornamental.
18 GOTHIC PROTHESIS Study on the Gothic Structures Structural analysis of the flying buttress shows the force acting on the model. The direction of the acting forces was collected and translated into several visual diagrams. It was discovered that the data collected closely resembles the original form of the flying butress. This shows how the gothic builders put a considerably detail effort in the conception of their design and proves that behind the poetic gothic structure outlook, there is practicality.
19 GOTHIC PROTHESIS
load
Compression
Flying Buttress Base Model
Tension
20 GOTHIC PROTHESIS Principal Stress Vector Field Extracted From The Flying Buttress Model
Compression
Tension 1
Tension 2
Vector Field
21 GOTHIC PROTHESIS
Principal Stress Analysis Based on structural physics found in the design of reinforced concrete, tension stress is known to comprise of two components; tension 1 and tension 2 that acts perpendicular with each other to resist lateral support and bending moment within a structure. Agent-based tensile algorithm was developed to generate venationlike structure according to the direction of tension 1 vectors while making perpendicular connections with each other depending on their location as to emulate lateral support for tension 2. Venation articulation based on structural information could define a highly complex networks of tensile materials that accurately placed in the location that they needed the most while maintaining continuation in form to accommodate metal casting strategy.
Flying Buttress Structure
Tension-Active Agent-Agent Based Algorithm
Compression-Active Agent-Agent Based Algorithm
Prosthesis
22
GOTHIC PROTHESIS
Agent Behaviour_
GOTHIC PROTHESIS
23
24
Agent Behaviour_
GOTHIC PROTHESIS
The act of overlapping, repetition and adding has a similar meaning which is an additive materials method into the basic structure. A Gothic cathedral is designed with a skeleton in a big picture then elements are added, repeated and overlapped themselves and each contribute as a part to the whole cathedral. Elements consist of grouped shafts, ribs, vaults and traceries. The agent in the Agent based design by scripting keeps moving, following and reacting in accordance with circumstance, which has not only the data but also the code. It has double-sided faces which are code and also data themselves. They constantly transform each other, calculate themselves and make the gothic character itself by constant overlapping. When structurally needs to grow, agents add more agents and elements from the behaviours of agent to make it more stable. Moreover, it is also recognised as articulation of structure. This integration system with a computational design algorithm gives influences to set the basic logic of the Pixelstone Project.
connection between other stress value points
connection lines
low stress
low tension value part
high tension value part
stress value
high stress
leave trail
25 GOTHIC PROTHESIS low stress
point clouds
iso surface
stress value
low
high stress value points : compression structure
high
high stress
low stress value points : tension structure
26
GOTHIC PROTHESIS
GOTHIC PROTHESIS
27
28
GOTHIC PROTHESIS
29 GOTHIC PROTHESIS The structure of Gothic architecture works as a whole system in architecture with a repetition element to consist of the part and the whole. This system of recursion and repetition reanalysed Gothic architecture. It is very similar to the system of nature principle which reads their part and works by repeating themselves for a million kinds of proportions and resultants. In the same way, with the gothic properties, gothic began as a simple theory and evolved as a complicated system with a surrounding fractal structure and organised space. Gothic is a conjunctive system composed with structure, space and ornament. All of these elements of Gothic properties were repeated and overlapped to organise of the space for the architectural elements. Like the repetition and overlap, the structural algorithm needs to follow these properties. For example, on the side of making the structure, when structures get a high stress point, they take the following steps: duplicate and repeat themselves, support the weak areas of structure with overlapping as much as needed and then complete designing the structure. The overlapped elements become structure and ornament at the same time and derive the architectural space.
30
GOTHIC PROTHESIS
GOTHIC PROTHESIS
31
32
GOTHIC PROTHESIS
GOTHIC PROTHESIS
33
34
GOTHIC PROTHESIS
GOTHIC PROTHESIS
35
36
GOTHIC PROTHESIS
GOTHIC PROTHESIS
37
38
GOTHIC PROTHESIS
GOTHIC PROTHESIS
39
41 MICROSTRATA 0 . 5 _ M I C R O S T R ATA Microstrata researches fabrication technique to create artificial sandstone with casted rebar, proposing a reinvention of reinforced concrete. The computational logic of agent-based algorithm is employed in the creation of interconnected, fine networks of venation with high-resolution according to tension structural data. From the initial investigations into compression-based fabrication in both conventional method and in digital fabrication, material that is widely used such as concrete proves to be highly unsustainable and time-consuming. While plaster, which is currently being used in large scale 3D printing process could only perform as a self-supportive structure with mass-like design. In order to achieve a high-resolution, intricate rigid structure, the idea of reinforced concrete is reinterpreted into metal casting technique which results in tension networks with structural performance adequate to that of conventional rebar. Compression blocks are fabricated by additive manufacturing method with high precision, leaving interconnected networks of cavities for tension material casting. As a fine aggregate material, the minimum unit of the sand marks the maximum resolution possible. For MICROSTRATA, a drop measures 5 square millimetres in size, which suggests a promising potential for high-resolution architectural scale fabrication. Taken in consideration the operational parameters of the robot, compression blocks are proposed to be printed in parts off-site. The blocks will then be transported, and assembled on-site by construction crane. Followed by on-site metal pouring process which results in robust tension networks that form structures, and at the same time bind the compression blocks into a single complete structure. Excessed compression parts which are predesignated in the design process are then removed by milling method, partially revealing intrigues from the networks of intricacy.
42 MICROSTRATA Conventional reinforced concrete is constructed on a grid-based basis, resulting in high level of material wastage. MICROSTRATA material deposition system is calculated in regards to structural data. Branching logic is adopted in the creation of high-resolution structure with a more organic expression, unbounded by any restrictions.
43 MICROSTRATA Liquid Metal
Air Holes
Compression Material: Sand + Plaster
Tension Material: Metal
44
MICROSTRATA
45 INITIAL FABRICATION
Phase 1 INITIAL FABRICATION
46 INITIAL FABRICATION Handmade 3D Printing
3D Printi With Frame
47 INITIAL FABRICATION 1 . 1 _ M AT E R I A L S In order to fully understand the basic parameter of additive manufacturing method in regards to the project, manual 3D printing is explored in the initial material research process. Sand is 3D printed in layers by using stencils. This method requires the use of frames in every printing layers, which is considered as an extra wastage. Moreover, stencils as frames are discovered to be more suitable for block-like, volumetric design which does not succeed in responding to the research’s aim for high-resolution fabrication. Metal casting is explored in this process. Low-melt alloy is tested with wax and plaster. It is evident that casting liquid metal into a structure would require air vents to lessen down the temperature. This material research yields crucial issues for fabrication method, in which is later developed as a criteria in the algorithm.
48 INITIAL FABRICATION Material : Sand Binder : Glue + Water (1:1)
Material : Sand + Plaster (1:1) Binder : Water
Material : Sand + Cement (1:1) Binder : Glue + Water (1:1)
Material : Sand + Plaster (1:1) Binder : Glue + Water (1:2)
Material : Cement Binder : Water
Material : Sand + Plaster (1:1) Binder : Water Coating : Epoxy Resin
Material : Sand + China Clay + Icing (1:1:1) Binder : Water
Material : Sand + Plaster (6:1) Binder : Water
49 13 Cm 15 Cm
Material : Sand Binder : Salt + Water (1:4)
18 Cm
11 Cm
21 Cm
Material : Sand / Plaster (2:1) Binder : Water
20 Cm
12 Cm 26 Cm
Material : Sand / Plaster (2:1) Binder : Water
INITIAL FABRICATION
20 Cm
50 INITIAL FABRICATION Metal Casting In Glass Wax
51 INITIAL FABRICATION Metal Casting In Plaster Mold
52 INITIAL FABRICATION Air Hole
AIR HOLE
Low-Melt Alloy
Metal Casting Tool
53 INITIAL FABRICATION Assembled Pieces Unified By Casted Alloy
54 INITIAL FABRICATION Average Diameter (Mm) 3 mm 1.43
4 mm
1.36
5 mm
1.20
6 mm
1.18
55 INITIAL FABRICATION 1 . 2 _ R O B OT I C F O R FA B R I C AT I O N
In order to increase resolution, the imrpoved method of manual 3D printing is depositing sand by dropping. This allows for the creation of any shapes without restrictions of the frames, as well as optimising executability. Machinic precisionism that could only be achieved by the use of robots is speculated in this phase, with the development of robotic tools. Tool version I, the proto simple tool to investigate sand dropping/binding system.
56 INITIAL FABRICATION
Our fabrication logic has been referred several examples. First logic was referred Stone spray project (IAAC) for spraying a binder system. The tool had a hole for releasing powder material controlled by a motor. The hole was opened on the place where the model should be printed then at the same time a binder was splayed on the point. Ideally the powder material was solidified soon by a binder, it could go next layer to print.
Compression Tool Version I Robotic
57 INITIAL FABRICATION Arduino
Servo
Liquid Binder Spray
Sand Deposition
Connection To Robot
58
INITIAL FABRICATION
Robotic Operation
59 INITIAL FABRICATION Sand Tank Water Tank
Nozzle For Compression
Work Place
Work Space
Both water and sand nozzle need to be supplied its material for print. We also designed work space for it. Water and sand material keep being suplied using gravity, material stations have to be higher than tool attached on the robot. Moerover, printing bed needs to be lifted up so that making it easier to modify/ reprace printing models.
60 INITIAL FABRICATION
However, there were a few problems on both the tool and tool path. With the tool, because we use plaster in the powder material, its dense character blocked the hole for releasing material. As the place of depositing powder had to be extremely precise, the hole could not be bigger. Furthermore, the moments of opening the hole and spraying a binder were not match all the time because we controlled them by timing. Eventually sometimes it release either too much powder or liquid material, totally lost its control. With the tool path, we set the tool path only on the printing model which was cut by plans every certain distance and filled it up by certain distance lines according to the experiment of depositing powder material (The distance could depend on the size of the powder putting hole but the smallest distance, for example, was 2.5-3mm to fill up the line between with the material). Yet the actual model does not go only vertical direction, if the next layer shift a horizontal direction, underneath of the printing points need to support its top. In other words, the powder material needed to be put wherever on the printing points or not to support next layers.
Tool And Robotic
Robotic Operation
INITIAL FABRICATION
61
62 INITIAL FABRICATION
1 . 3 _ R O B OT I C TO O L PAT H
Tool Path
63 sandstone with casted rebar. The computational logic of agentbased algorithm is employed in the creation of interconnected, fine networks of venation with high-resolution according to tension structural data. While compression structure is realized by erosion method, revealing highly articulated surface. From the initial investigations into compression-based fabrication in both conventional method and in digital fabrication, material that is widely used such as concrete proves to be highly unsustainable and time-consuming. While plaster, which is currently being used in large scale 3D printing process could only perform as a self-sup
2mm
3mm
3mm
Fabrication Strategy
INITIAL FABRICATION
Microstrata researches fabrication technique to create artificial
64
INITIAL FABRICATION
65 INITIAL FABRICATION Prototype Evalutation
66 INITIAL FABRICATION
1 . 4 _ A D VA N C E D TO O L S T R AT E GY
From this test, we concluded that firstly we had to reconsider about powder putting system such as using air compressor or gear to keep pushing it. Secondly also spraying system needed to be more precise, could be used Arduino to control its timing. Thirdly the tool path cannot be only on the printing model but also around it. In this case, the printing model is printed with a binder first, afterwords stop spraying a binder and only putting dry powder material so that the dry part could be removed after printing whole of the model. Either water or sand nozzle can be more than one. From robotic tutor’s advice, these nozzle could be controlled with binary code by Arduino to make the printing process efficient.
67 INITIAL FABRICATION Sand Container
Water Nozzle
Connection To Robot
Alternative Tools
68 INITIAL FABRICATION 0
1 3
1
8
2
0
0
1
1
2
1
1
2 =8 2 =4 2 =2 0
2 =1
11
2
3
2
2
2
1
2
0
11
Binary Code Tool I
7
13
13
9
1
10
14
4
14
3
69 INITIAL FABRICATION 0
1 3
2 =8 2
2 =4
1
2 =2 0
2 =1
1
0
0
4
1
2
1
1 7 3 10 13 7
Binary Code Tool Ii
70
TEST CASE ; COLUMN
71 TEST CASE ; COLUMN
Phase 2 TEST CASE; COLUMN
72
TEST CASE ; COLUMN
73 TEST CASE ; COLUMN Conventional Reinforced Concrete Rebar
Microstrata Casted Reinforcement
2 . 1 _ M I C R O S T R ATA R E I N F O R C E D C O N C R E T E
Column prototype is a test-case that initiates the first step into material fabrication. With computational algorithm, tension and compression structures intertwine to form a self-supportive, load-bearing structure. Duality of operations are investigated. Based on casting technique, compression structure is created by the method of additive manufacturing, forming a mould for tension material casting. The prototypical column, with its compression and tension active properties, stands as a strong support with decorative features of micro articulations.
74 TEST CASE ; COLUMN
2 . 2 _ M I C R O S T R ATA C O L U M N A LG O R I T H M _ V. I
In the beginning, to design algorithms, agent based design was used so that agent would follow the structure data of the basic column. Multiple agents are reacted to direction of compression and stress value of tension that connect to each other when it gets compression needs while it does not make connections among agents to make cavities of tension network with rebar. As we can see, the section coloured black filled section has compression , however, cavities are there for to make metal be casted. It is clear that a particular logic is needed for the tension network algorithm to work for structure to be strong, also for compression behaviours layer-by-layer. The algorithm of the structure should be interacted together between compression and tension factors; both materials’ algorithms should be reacting to each other so that their material is constantly fabricated. When it comes to computational design, we can set parameters which can affect results such as amount of space needed, structural tolerance or properties of space. In accordance to parameters, spaces are made and optimised topologically. We call this topological optimisation.
Connection Between Trails
connection between trails
Tension low Low tension area ( dense / connection) Area
High Tension high tension area (void / no connection) Area
vector fields Vector Fields Vector Fields
agentsDeposition deposition Agent Deposition Agent
agent’s trails Agent Trails Agent’s Trails
Connectes Trails connected trailsTrails Connected
75 TEST CASE ; COLUMN High Tension Area : Void/No Connection
76 TEST CASE ; COLUMN Metal Casting metal
Compression Structure compression structure : snad + plaster
Structure tension Tension structure : metal
COLUMN PROTOTYPE STRATEGY
77 TEST CASE ; COLUMN Fluide Surface Simulation
FRAME = 10
FRAME = 50
FRAME = 200
FRAME = 250
FRAME = 300
FRAME = 350
FRAME = 400
FRAME = 450
Column Process
TEST CASE ; COLUMN
79
80 TEST CASE ; COLUMN Structure Data
Agent-Based Behaviour
81 TEST CASE ; COLUMN
2.3_ CAVIT Y COLUMNS
The cavity columns are initial simulations of the research project’s concept in creating metal reinforced structure. The algorithm serves the design intent to redefine the idea of a rigid column that mostly works in compression. Cavity column is generated with porosity and high-resolution. Vertically nested according to the parameters, the column is left with continuous networks of cavities which allow for metal casting. The computational logic is later applied in Multi-columns for larger scale speculation, resulting in a multi-material aesthetics of rationality.
Compression Mass
Casted Tension Network
82 TEST CASE ; COLUMN BEHAVIOUR INFORMATION
Part Process
TEST CASE ; COLUMN
83
FRAME = 100
FRAME = 150
FRAME = 200
FRAME = 250
FRAME = 300
FRAME = 350
FRAME = 400
FRAME =450
FRAME = 500
85 Microstrata researches fabrication technique to create artificial sandstone with casted rebar. The computational logic of agent-based algorithm is employed in the creation of interconnected, fine networks of venation with high-resolution according to tension structural data. While compression structure is realized by erosion method, revealing highly articulated surface. From the initial investigations into compression-based fabrication in both conventional method and in digital fabrication, material that is widely used such as concrete proves to be highly unsustainable and time-consuming. While plaster, which is currently being used in large scale 3D printing process could only perform as a self-sup
TEST CASE ; COLUMN
2 . 4 _ M U LT I - C O L U M N S
86 TEST CASE ; COLUMN Sand Deposition
Binder Spray
Binder Spray Frame
Tool Path V.ii
87 Under the first logic experiment, we developed second fabrication logic referred zcorp 3D printer. As we still could not fix the problem of putting powder material, we decided to focus on use the liquid material first. At this stage, we changed the printing logic following zcorp printer. The process was putting dry powder material first and flatten it, then depositing liquid binder on the printing model shape. It worked layer by layer again, the parts without liquid binder remained dry texture then worked as supporting material for next layer. The improved tool had a roller to flatten powder material and a needle to deposit liquid. The roller was attached with a motor to change its level because when the roller flattens the powder, it should touch on the surface of the powder bed and when the liquid was released, it should not touch on the surface. The liquid releasing was controlled by a solenoid valve connected with Arduino which could only open on the printing model. We used the same tool path for the initial test of the tool, however, even with the solenoid valve, it was hard to leave holes inside of the model because only on the parts of the hole had to be left as dry and the holes were relatively fine networks.
TEST CASE ; COLUMN
2.5_ PRINTING COLUMN
88 TEST CASE ; COLUMN 0.89 Mm
1.10 Mm
1.30 Mm
Needle Variation
TO O L PAT H I N F O R M AT I O N
To solve the problem, we improved tool path with using single line as drawing outlines of tension networking pipes. Because the line size after slidified water should be fixed for the calculation of toolpath, first we tested it with several needles.
89 TEST CASE ; COLUMN FAST SLOW
FAST SLOW FAST SLOW
0.8 mm
Nozzle Material Experiments
90 TEST CASE ; COLUMN
2.6_ TOOL DESIGN
Our tool is improved for the new toolpath logic as well. It is attached sand flattening and water release fanctions on one tool. TCP points for sand and water have to be different levels, we add a motor to rotate a part of tool.
Sand Nozzle
sand nozzle
30째
Water Nozzle
water nozzle
91 TEST CASE ; COLUMN
Water Nozzle
Sand Nozzle
Supporter Sand Tube Connection
Motor
Robot Connector
Rotation Base
Swipe
92
TOOL
TEST CASE ; COLUMN
This tool with rotating 2 tools according to the toolpath make us the printing process faster. The process is; 1, putting sand and flatten it by sand tool. 2, rotating tool into water tool. 3, drawing contour courves by water tool. 4,drawing frame . This process will repeat every layer.
Flatten Sand
Drawing Frame / Model
Tool Movement
93 TEST CASE ; COLUMN sand nozzle
placeNozzle sand Sand
Deposits Sand
water nozzle drawNozzle model Water
Draws Model Tool Path
water nozzle draw frame
Water Nozzle Draws Frame
Tool Movement
94 TEST CASE ; COLUMN Deposit Sand
Flatten Sand
Draw Tool Path
95 2mm
TEST CASE ; COLUMN
PRINT OUTPUT
3mm
3mm
Although sand flattening tool and water nozzle work well in the experience, it is still hard to put sand automatically with a tiny tube attached on the tool. In addition, controlling the timing of releasing water cannot be presice as much as we expexted. Even with sound and waiting time on each target, we cannot aboid delay. Eventually we succeed to produce higher leveled model. However since the controlling issue of water, output model is just following approximate shape of input model. Moreover we cannot build a box shape as sand always slipes from the top at the certain height. It might be better to use pyramid shape for bounding box.
Printed Column Ptototype
96
DLA / OPTIMISATION
97 DIGITAL TENSION NETWORK
Phase 3 DIGITAL TENSION NETWORK
98 DIGITAL TENSION NETWORK In order to work as compression structure and trial for DLA system, topological optimisation was conducted as an experiment. There are already various kinds of topological optimisation programs. Topological optimisation is a method to find an optimised material layout with a mathematical approach for design and structural space. It makes a base layout have a different shape due to different sets of load and fixed ground. Thus, designers and structure engineers can find design requirements and concepts easily. It is a good beginning for prototyping columns which will be experimented by the DLA extended Microstrata algorithm.
99 DIGITAL TENSION NETWORK Topological Optimisation
Compression
Tension
100 DIGITAL TENSION NETWORK
3 . 2 _ V E N AT I O N SYS T E M _ L AY E R
The reason to have a topologically optimized shape is to get its own data about structure and it needs the tension network to be an architectural space in reality; it could grow itself by layer-by-layer. With the vein system for tension, there are a lot of references to leaf venation, fractal structure and DLA(Diffusion-Limited Aggregation). The venation system follows values of tension stress that makes connections by duplicating itself and moving to other stress points. DLA is a different type of vein system which makes tension networks inside of a column.
Connect To Neighbouring Points connect neighbours pointsc
Create Springs reate springs
Find High Stress Value Points find high stress value points Create New Branches
Create Network create network
create new branchs
Venation System
101 DIGITAL TENSION NETWORK FRAME = 100
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3 . 3 _ V E N AT I O N S T R ATA 102
Microstrata researches fabrication technique to create arti-
DIGITAL TENSION NETWORK
ficial sandstone with casted rebar. The computational logic of agent-based algorithm is employed in the creation of interconnected, fine networks of venation with high-resolution according to tension structural data. While compression structure is realized by erosion method, revealing highly articulated surface. From the initial investigations into compression-based fabrication in both conventional method and in digital fabrication, material that is widely used such as concrete proves to be highly unsustainable and time-consuming. While plaster, which is currently being used in large scale 3D printing process could only perform as a self-sup
root points Origin Points
Stress Value Points stress value points
103 DIGITAL TENSION NETWORK FRAME = 100
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104
DIGITAL TENSION NETWORK
DIGITAL TENSION NETWORK
105
106 DIGITAL TENSION NETWORK Basic DLA Random Formation
DLA Tension Algorith Stress Directional
107 Particles and connections along particles are handled with growth in itself in random ways. For example, Andy Lomas, he is an artist whose work is based on mathematics. His work ‘Growth Aggregation’ has a DLA basis, working with random directions; however, he also used the force of gravity and centrifugal force to design his work. The particles grow themselves in a particular direction of force; according to his mathematical formula his code makes some catalogues. He illustrates that art and sculpture have a possibility of a mathematical basis as parametric design and DLA can be affected by external force and internal force. Thus, the Microstrata algorithm is a upgraded version of DLA that grows through the direction of tension or compression stress value and makes a consequence network which works as a tube for casting rebars.
DIGITAL TENSION NETWORK
3 . 4 _ D I F F U S I O N L I M I T E D A G G R E G AT I O N
Basic DLA Random Formation
FRAME = 100
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FRAME = 250
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FRAME = 350
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FRAME = 650
109 FRAME = 100
FRAME = 150
FRAME = 200
FRAME = 250
FRAME = 300
FRAME = 350
FRAME = 400
FRAME =450
FRAME = 500
FRAME =550
FRAME =600
FRAME = 650
DIGITAL TENSION NETWORK
DLA Tension Algorith Stress Directional
110 DIGITAL TENSION NETWORK particles : N1P24015 CurveAlign : 0.7 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 0.1 Density : 4 ParticleRadius : 0.25
particles : N1P25999 CurveAlign : 0.7 CurveSpeed : 0.02 SpawnRadius : 24.0 Stickiness : 0.1 Density : 8 ParticleRadius : 0.25
particles : N1P26781 CurveAlign : 1.0 CurveSpeed : 0.2 SpawnRadius : 24.0 Stickiness : 0.1 Density : 8 ParticleRadius : 0.25
particles : N1P28227 CurveAlign: 0.7 CurveSpeed : 0.2 SpawnRadius : 24.0 ST : 0.1 Density : 8 ParticleRadius : 0.25
particles : N1P35698 CurveAlign : 0.1 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 0.1 Density : 8 ParticleRadius : 0.25
particles : N1P36304 CurveAlign : 0.7 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 0.1 Density : 8 ParticleRadius : 0.5
particles : N1P36371 CurveAlign : 0.7 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 0.1 Density : 8 ParticleRadius : 0.9
particles : N1P37697 CurveAlign : 0.7 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 0.1 Density : 8 ParticleRadius : 0.25
111 DIGITAL TENSION NETWORK particles : N1P34917 CurveAlign : 1.0 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 1.0 Density : 8 ParticleRadius : 0.25
particles : N1P35145 CurveAlign: 0.7 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 0.1 Density : 8 ParticleRadius : 0.01
particles : N1P37699 CurveAlign : 0.5 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 0.1 Density : 8 ParticleRadius : 0.25
particles : N1P38755 CurveAlign : 0.7 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 10.0 Density : 8 ParticleRadius : 0.25
particles : N1P35155 CurveAlign: 0.7 CurveSpeed : 0.002 SSpawnRadius : 12.0 Stickiness : 0.1 Density : 8 ParticleRadius : 0.25
particles : N1P41409 CurveAlign : 0.7 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 1.0 Density : 8 ParticleRadius : 0.25
particles : N1P35556 CurveAlign : 0.7 CurveSpeed : 0.002 SpawnRadius : 24.0 Stickiness : 0.5 Density : 8 ParticleRadius : 0.25
particles : N1P44307 CurveAlign : 0.1 CurveSpeed : 0.002 SpawnRadius : 12.0 Stickiness : 1.0 Density : 8 ParticleRadius : 0.25
112 DIGITAL TENSION NETWORK Tension Stress Lines
Set Up
DLA Reaction
Topological Optimisation
Tension Network Through Layers
113 DIGITAL TENSION NETWORK
3 . 5 _ D L A w i t h TO P O LO G I C A L O P T I M I S AT I O N
In order to work as compression structure and test for DLA system, topological optimisation was conducted as an experiment. There are already various kinds of prefabricated topological optimisation programs. Topological optimisation is a method to find an optimised material layout with a mathematical approach for design and structural space. It makes a base layout have a different shape due to different sets of load and fixed ground. Thus, designers and structure engineers can find design requirements and concepts easily. It is a good beginning for prototyping columns which will be experimented by the DLA extended Microstrata algorithm
MICROSTRATA DLA
114 DIGITAL TENSION NETWORK
3.6_ COLUMN PROTOTYPE_DLA
The experiments to make column prototypes, it is clear that DLA and Topological optimisation have problems which the Microstrata algorithm can only complement defaults of both sides structural and design features thus it is not absolute optimization. Since random features established the DLA system and a simutils developed system avoiding collision among particles, it is not systemic rebar as a structure in contrast to the practical rebar system which is based on a grid system and connections between horizontal or vertical structures. The rebar system should be more practical and more organised. In terms of topological optimisation, running the DLA algorithm into outcome is meaningless, because it has already calculated every structural problem.
Column Agent Behaviours
115 DIGITAL TENSION NETWORK Column Prototype Catalogue
116 DIGITAL TENSION NETWORK Compression I
Compression Ii
Tension I
Tension Ii
117 DIGITAL TENSION NETWORK Compression I Compression Ii Tension I Tension Ii
118 DIGITAL TENSION NETWORK Compression
Tension I
Tension Ii
119 DIGITAL TENSION NETWORK Compression Tension I Tension Ii
120 DIGITAL TENSION NETWORK Compression I
Compression Ii
Tension I
Tension Ii
121 Compression I Compression Ii Tension Ii
DIGITAL TENSION NETWORK
Tension I
122 DIGITAL TENSION NETWORK
Compression
Tension I
Tension Ii
123 Compression I Tension Ii
DIGITAL TENSION NETWORK
Tension I
124 DIGITAL TENSION NETWORK 3 . 7 _ A R C H I T E CT U R A L D L A S PA C E
Microstrata researches fabrication technique to create artificial sandstone with casted rebar. The computational logic of agent-based algorithm is employed in the creation of interconnected, fine networks of venation with high-resolution according to tension structural data. While compression structure is realized by erosion method, revealing highly articulated surface. From the initial investigations into compression-based fabrication in both conventional method and in digital fabrication, material that is widely used such as concrete proves to be highly unsustainable and time-consuming. While plaster, which is currently being used in large scale 3D printing process could only perform as a self-sup
Space Prototype Catalogue
DIGITAL TENSION NETWORK
125
126 DIGITAL TENSION NETWORK
3 . 8 _ FA B R I C AT E D L A S PA C E
It has already pointed in the voceljet example section, if this project focus on the real architectural scale, the joint design is necessary. The advantage of printing by pieces is that it could save the construction time, space and materials because the main structural components, which is compression structure bricks in the pixelstone project, are produce in factories. The proposal of pixelstone construction process would be firstly printing bricks off site and shipping to the site. Secondly assembling those bricks then pouring tension material on site. In the process of pouring tension material, every piece would be attached together even stronger. To take this method, construction process would become much simpler, which only needs shipping cost and construction of pouring tension material.
Excess Material Deposition : Cavities For Metal Casting
Excess Compression Milling : Revealing Tension Network
127 DIGITAL TENSION NETWORK Compression Stress Line
I. Off-Site Block Fabrication
Iv. Metal Casting : Tension Network
Ii. Transportation
Blocks Divided According To Stress Direction
Iii. On-Site Assembling
V. Milling Out Excessed Compression Parts, Revelaing Tension Network
128
DIGITAL TENSION NETWORK
DIGITAL TENSION NETWORK
129
130
DIGITAL TENSION NETWORK
Phase 4 Linear Fabrication DIGITAL TENSION NETWORK
131
132 RECURSIVE_LINE
4 . 1 _ A R T I C U L AT I N G T E N S I O N N E T W O R K
Recursion is the process of repeating items in a self-similar way. Hierarchical order is intuitively generated by the repetition of a form in different directions and scales, creating complex elements but retain the overall order in logical way. As being discussed in [chapter 2], recursion and fractal system can always be found in the natural living organism, vegetation and mineral formations. Subconscious understanding by living beings with this form denote that the recursive system is in no way artificial but embedded within our complex genetics. With this, we investigate the possibility of including recursive system within the agent-base algorithm to generate intricacy in the tension network formations. The projected outcome is a high-resolution metal reinforcement network composed by local reaction to structural data within the whole structure.
AUFLĂ–SUNG
Workshop With Benjamin Dillenburger
RECURSIVE_LINE
133
134
4.2_ RECURSIVE TENSION NETWORK
RECURSIVE_LINE
As a result of the material test, research found more necessary elements in the project. It is not only for a view of design, but also that of the fabrication manner. The essential character of material was passed to cast the metal form. From the experiments about casting metal into moulds, we discovered that air vents should be provided to channels for hot pressure air out from the mould. Thus every tension mould needs an air vent to prevent liquid metal from exploding. The air vent algorithm is working with avoiding tension network which already exists. This is because once it is connected with them, the channel could be
blocked by liquid metal then it will not work for an air vent as it should move with avoiding other agent trails. In addition, the tension network is grown as a venation system which has millions of tubes of branches. However, agent begins to grow as random position as following tension stress lines. It is apparent that metal could not be casted through all of the branches. Therefore, millions of branches channels should be assembled to make open gates be available to pouring metal. This system is from a recursive system [FIG_27] which looks
compression
tension 1
Stress Direction stress direction
Compression compression
tension 2
Tension1 tension 1 stress direction
Tension2 tension 2
Tensionhigh High Stress Value tension tension stress value high stress value
Compressioncompression High Stresscompression Valuestress value high high stress value
Principal Stress
135 RECURSIVE_LINE Test Case II : Coffee Table
136 RECURSIVE_LINE
after themselves and sets new points where it is efficient to be casted as it is likely that it will not be obstructed by gravity works. For example, casting channels are complicatedly entangled, it will not be easy to cast even it has an efficient air vent. Hence, to determine casting points and channels it is more efficient and simpler to enhance abilities by finding the closest point from the surface and the shortest path from the casting point to tension network channels.
Recursive Tension Network
ISO Surface Compression Section
137 RECURSIVE_LINE Test Case II : Coffee Table
RECURSIVE_LINE
139
VERSION I
Version Ii
Since the pallerel lines tool path did not work well because of the timing of releasing water, we changed the tool path logic to printing single line so that making less controlling timing of releasing water. The model should be transfered into contour curves as input data. To control the distance of curves on each layer, we manage to get casting channels with shell like compression structure. The line weight depends on water pressure and robot speed, we have to calcurate water expansion.
Draw Model Tool Path
Water Expands
Lines Connect/Form The Model
141 RECURSIVE_LINE
4.3_ PRINTING CONTOUR DRAWING
142
4.4_ BOUNDARY OF PRINT RANGE
RECURSIVE_LINE
by solidifying sand in layers through a linear tool path, compressive nature of the material requires us to contain unbinded supporting material in place. Normal SLS 3D printer use a bucket-like container within the machine to hold the article together. Since we are using robotic arm, we device our own method of generating a ‘container’ by printing additional perimeter bounding box enclosing the model. After curing process, the pyramid-shaped box retain it’s shape and the material within, keeping the printed model intact.
1 : Dry put dry sand and flatten 1 : Put Sand And Flatten
2 : draw outlines ofOf a model 2 : Draw Outlines A Model
: draw frame as aAs pyramid 3 :3 Draw Frame A Pyramid
143 RECURSIVE_LINE Tool Path Model/Frame
Robotic Operation
144
RECURSIVE_LINE
145 RECURSIVE_LINE
24 cm
13 cm
MATERIAL : SAND + PLASTER (1:2) BINDER : WATER
20 cm
Contour Printing Prototype
146 RECURSIVE_LINE MICROSTRATA PRODUCT FRUIT BOWL
147 RECURSIVE_LINE
4 . 4 _ M I C R O S T R ATA P R O D U C T S
148
RECURSIVE_LINE
Cleaning Process
RECURSIVE_LINE
149
4 . 5 _ C A S T I N G A LT E R N AT I V E R E B A R
After coated by protecting material such as resin on the surface, the model will be casted artificial rebar. This material will work in tension, so we can make cantilevering structure. Additionally this tension casting material work as connection between piece and piece, could glue them strong. We have had experiment with low melting alloy due to the material will suppose to be metal. However for the larger scale physical model, we use resin and fiver glass as alternative tension material and cast in the channels. As resin works well as tension material, we succeeded the model attached together. Although some of the channels are destroyed during the process of its fabrication, resin leaks from every holes, eventually the resin solidify relatively in short time. The final model keeps its shape even stronger.
Casting Process
RECURSIVE_LINE
151
RECURSIVE_LINE
153
RECURSIVE_LINE
155
156
BRANCHING SYSTEM
157 BRANCHING SYSTEM
Phase 5 Branching System
5.1_ BRANCHING REINFORCEMENT BAR
1
2
159 BRANCHING SYSTEM
Microstrata computational logic is making high resolution of tension network from a few beginning points with growing rebar system. The rebar from one point became countless numbers of those by calculating and responding to the environment every moment. The computational algorithm is derived from the real rebar system. The tension network by branching system agents are looking for demand for structure and moving the position to make the network depend on the real scale of distance among the rebar. From the DLA system to the venation system, this logic demonstrates branching the rebar system due to the stress line and value based on a factual arrangement theory about rebar. With practical information, the algorithm of it will be more feasible to the work structure. On the other hand, in a view of structure, only rebar cannot work as a compression structure, then another algorithm which is working for compression by adding material where the structure is weak. We generate multiple computational algorithms for multiple materials. Research has been made about cantilever and column rebar arrangement; it has a certain distance between rebars, which is caused by volume and proportion of the whole structure and material which is a composite of compression or tension. For example, the main rebars which are working on vertically, has an average distance of 300mm when the diameter of metal rebar is 13mm. They calculate each other’s dimensions then they make themselves have a wider distance when diameter of rebar is thicker. In the same manner, this algorithm involves basic algorithm to arrange rebars.
Computational Adaptation from Conventional Rebar System Prototype of Branching System
159
161 BRANCHING SYSTEM Tension
additional compression support
Compression
BRANCHING SYSTEM
163
164 BRANCHING SYSTEM Tension I
Tension II
Compression
tension 1
tension 2
compression Structural Stress Line
tension 1
tension 2
compression
5.2_
STRESS AND BRANCH
Stresslines are perpendicular, we can find the direction of the structural stress. Every geometry includes structure lines and data about both tension and compression. Stresslines indicate the directions for the computational behaviours. Throught the structure infromation, an algorithm is the procedure to discover a solution to a problem, which after a finite number of steps, stops, and finally leads either to a solution to the initial problem or not. As a result an algorithm is a group of procedural rules of instruction. Multiple processes operate multi-algorithms for multi-materials. Each step subsequently generates different information for the next process. First step, it grows branches with finding node points where perpendicular connections will be fastened among the branches, which are aroused from stress values. The higher the stress demand for tension elements, the denser the connection
Bone Structure
165 BRANCHING SYSTEM Branching Algorithm
is that are supplied. While 90 degrees connections suspend every branch, new tension structure is produced and optimised by computation. It is determined to be a less stable area for the compression side by calculating the structure itself. As mentioned above, structure cannot stand alone with only tension structure. In opposite to compression structures which can standalone, tension structure needs a compression material’s assistance. Agents, which contribute to compression trace areas, of which structure is unstable to stand by itself. The area where it needs a support of compression is called the attracting point to attact compression agents to add materials. They are not only attracte but also find unstable areas space itself without tension network. Corresponding to stress value and the amount of attracting points, different number of agents generated and overlapped at the area. In order to materialise, they generate agent traces, which will be the sand section mainly towards the ground to support the structure.
Branching Tree
Tension I Branching Algorithm
distance
distance
tension 1
low stress value
tension 2
high stress value
167 BRANCHING SYSTEM
Tension II Connection Algorithm
Casting Point Algorithm casting distance
Casting Point
casting distance
attractor by high stress value
compression
169 BRANCHING SYSTEM
Compression Attractor Algorithm
5.3_
V O X E L I Z AT I O N
170 BRANCHING SYSTEM
The Pixelstone algorithm is established with linear trails to achieve a tension network and compression solution. Despite using the linear way, we should transfer trails to horizontal layers techniques due to our material sand’s properties. As following material tests and fabrication tools, it is obvious to shift from line to point as a design method. Material as a powder based on particle, fabrication as a direct method from programs and scripting as finishing shapes for design, these are focused on performing a high resolution level of architecture and fabrication without losing any parts. In order to concentrate on transfer linear trails on layer and material properties and also get fabrication sources directly from script, Voxel gird system and Cellular Automata provide methods to accomplish computation design and computer controlled fabrication. Every linear trail is played in the multi dimensional grid of voxel system so that they are easy to be voxelised . Every 3D votel grid system detects agents and trails moving and transfers the centre point of basic box which consist of voxel.
Tension + Compression Network Agent
Material Arrangement
Gravitational Response / Reinforcement Materials
171 Tension
Compression
BRANCHING SYSTEM
Air Vent
Cellular Automata is a self-update system according to neighbours’ states in grid systems. This rule helps our algorithm to actualise in the
172
voxel grid with linear trails. Materialising is divided into two systems, one is making solids for compression and the other is making cavities inside for tension to be casted metal and air vent to air flow. Tension material
BRANCHING SYSTEM
always produces rounded arrangements to make channels while maintaining void space following the tension network for metal casting. On the other hand, compression material always has a cross arrangement of material to optimise compression values. These two systems always interact together to solve a problem, which interrupts working two different type of materials as they get overlapped and invaded each others’ territory. A grouped cluster of tension networks should maintain a void as a channel for metal casting and a grouped cluster of compression crosses are overlapped together to generate a denser mass for support. The problematic section is both elements which locate at an intricate position. Complicated interactions emerge between making solids and voids and the tension network void is given priority to join. The whole project structure is contoured by layer which is determined by fabrication logic. Layers optimise previous layers according to the location of voxels. Pixelstone has a test case and a prototype with an algorithm. As a result of scpriting, we achieved 3mX3mX3m prototype arhictectural chunk. Following the script frame, it calculates stress point, makes branches, connect following the values, make attrators by itself and recurse itself to make casting channels. Then Compression agents generate compression trails following attractor points and compression vector field. With both trails, air vent agents avoid to collide other trails and move toward surface. After all of agents trails are finished reacted for structure, Pixelstone voxelize rule converts trails to voxel. The point cloud of model will directly exported to robot and will be printed.
Voxel Space
173 Material Arrangement in Agent Solid & Void Resolution
Solid Compression
BRANCHING SYSTEM
Tension Network Agent
174 BRANCHING SYSTEM Multi Agents Behaviours
Voxel Details
Voxelize Automata
BRANCHING SYSTEM
175
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FRAME = 750
FRAME = 900
177 BRANCHING SYSTEM FRAME = 400
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FRAME = 1600
178 BRANCHING SYSTEM
5.4_
SUBTRACTION
To reveal the intricate tension network within the compression mass, some part of the model need to be removed. We do this by identifying a region with the lowest compression stress value, which means less compression material are needed. It also mean that this area is inherently high tensional region and most of metal reinforcements can be found.Through specifically designed algorithm, this region is 'eroded' based on the overall stress value embedded in the model.
3 meter Volume`
Space Eroded
Part to be Taken Our
179 BRANCHING SYSTEM putting in spring matrix
putting in Spring Matrix
finding the model shape
finding the Model Shape
attractingstronger stress places
attracting stonger stress area
after subtracting volume
after subtraction volume
FRAME = 150
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BRANCHING SYSTEM
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5.5_
A R C H I T E CT U R A L S PA C E
Microstrata is finding Architectural space to adapt and test algorithm in architectural scale. This space can be designed with same algorithm with branching system as alternative reinforced concrete and also have a same shape as real architectural space. Microstrata algorithm generates the architectural space through the branching, attractor and subtraction system. It finds structural stress value ponts cloud and stress directional line to help agents navigate and generate spcace according to the structure. Three structure lines which are for compression and both tension become basic guide lines. From the structure point cloud, multiple agents generate, follow tension stress line and dudlicate itself then make branches. In this process, tension network directions make other compression direction due to structure lines. Also compression agents follow new vector field and existed stressl lines and reinforce the structure of space by adding materials. This behaviours generated architectural space as column, slab, ceiling and so on. This space can be the first prototype space from Microstrata space. It illustrates how the alogorithm works on real scale space.
183 FRAME = 100
FRAME = 200
FRAME = 300
FRAME = 400
FRAME = 500
FRAME = 600
FRAME = 700
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FRAME = 90v0
BRANCHING SYSTEM
FRAME = 0
Tension I Stress Lines
Tension II Stress Lines
Tension I Branching
Tension II Connecting
185 BRANCHING SYSTEM Compression Stress Lines
Stress Value Points
Calculating Structure Value
Compression Adding Material
Finding Subtracting Area
Subtracting Compression Material
187 Compression Structure
BRANCHING SYSTEM
Tension Network
BRANCHING SYSTEM
189
Top Plan
0
1
2
4m
BRANCHING SYSTEM
191
BRANCHING SYSTEM
193
194
PRINTING VOXEL
195 PRINTING VOXEL
Phase 6 Printing Voxel
196 PRINTING VOXEL
6 . 1 _ T R A N S IT ION BETWEEN LI N EA R TO VOXEL MATRIX Binder material deposition test is conducted in support of the tool development. Moving from line-based contour crafting to printing voxels, dropping experimentations is a crucial study in order to obtain data for robotic toolpath. With different material with adhesive capacity for sand/plaster mix, the material behaviour is explored in terms of dropping distance, surface finishes, volume expansion, setting timeframe and deposition viscosity.
Nozzle Variation
197 PRINTING VOXEL Binder Position Test
198 PRINTING VOXEL Drop Distance Test
199 PRINTING VOXEL Colour Binder Test
200
PRINTING VOXEL
201 PRINTING VOXEL Binder Variation Test
202 PRINTING VOXEL Zcorp Binder
Plaster Polymer +10% Water
Plaster polymer, a water-base acrylic proves to be the best choice for binder mix. While drops of pure Jesmonite, with its high level of viscosity, stay on the surface of the powder which have negative effects regarding precision. The setting time of high viscosity material would effect the layer printing precision. As a water-based resin material, Jesmonite mixed with water could be used as binding agent between printed blocks in the assembly process due to its quality of high compressive strength.
Jesmonite
1:2 Jesmonite : Water
203 PRINTING VOXEL Appearnace
Jesmonite (Water Based Acrylic Polymer)
Plaster Polymer (10% Mas. Water Mixture)
Z corp Binder
Matt White on Top Surface
Cure Time Initial Set 25-30 mins at 16 - 18 째C
Expansion After Curing
Compressive Strength
Viscosity
1 Hour
30 Mps
High
1 Hour
25 Mps
Medium
1 Hour
12 Mps
Low
Final Set 2-3 HRS
Glossy White Clear Gloss on Top Surface
60mins at 20 째C
Clear
30mins
204
PRINTING VOXEL
205 PRINTING VOXEL
6 . 2 _ M ULT IPLE N OZ Z LE TOOL I N MATRIX
fabrication tool version 4.0
Connection towater Water Reservoir connection to reservoir
9mmdiameter Ø flexible hose 9mm Flexible hose
ABB adapter ABBrobot robot adapter 12V Valve 12VSolenoid solenoid valve 1mm Needle Tip 1mmdiameter Ø needle tip
125mm 125 mm
22 mm 22mm 72 mm 12mm
206 PRINTING VOXEL Tool V. 4.2 Tool Path Test
207 PRINTING VOXEL
Now the tool path can follow those voxels. Its logic states that as each nozzle has 5 lines of voxels, every nozzle goes for print its first line then shift to second lines and come for print and so on. Eventually when the nozzles print those 5 lines, all of the 30 lines of voxels are printed. After printing 30 lines voxels, the tool path shift to next 30 series of voxel lines where next to the 5th voxel line of 6th nozzle. When all of the voxels on the layer are printed, the tool path will move for flattening powder material for next layer and repeat the same process until the end.
22mm
direction of shifting
4.5mm
7mm
Printing Pixel Tool
208 PRINTING VOXEL
To use this new method, whole of the tool and tool path logic needed to be changed. The number of liquid releasing nozzles have been increased for 6 to make the printing process faster. Each nozzle has a solenoid valve so they can be controlled one by one. For the new tool path logic, input information had to be point clouds as we needed to drop liquid binder on those points. To get that exact information, both computational logic and fabrication logic had to work on voxel logic. The voxel size must follow the real size of one drop from the nozzle, which is 7mm diameter, make it sure to connect every single drops together, the ideal one voxel size is set with 4.5mm. The tool path logic became more complex this stage. As the tool path has to follow the voxel, first it needed original voxels for the measurement. The logic of creating voxels is from each x, y, z axis length of the bounding box, which depends on the robot, 300mm × 300mm × 300mm for IRB 120 for example, then divide by a certain number to create voxels from the bounding box. The 6 nozzles on the tool have already fixed that the diastase between 2 next nozzles is 22mm. If the voxel size is set 4.5mm, the number of voxels between 2 next nozzles should be 5. Therefore with one whole of the printing process can produce 30 (6 nozzles × 5 voxels) voxels per axis. In this case, the tool path completes every 30 series of voxels, the number of voxels pre axis must be a multiple number of 30. Overall, to make the voxel logic woke with IRB 120, the bounding box should be 270mm × 270mm × 270mm, divide by 60 per axis to get 4.5mm voxels.
ABB rb-140 Working Range
Tool V. 4.2 Multiple Nozzles
209 PRINTING VOXEL Tool Path Simulation
Multiple Nozzles Tool Path
210 PRINTING VOXEL
As the system of defining where each of the nozzle open and close its valve, the tool path reads 0, which means close, and 1, which means open, information. Namely if the printing point clouds are in the voxels, the voxels create 1 information, if not, create 0 information. After this process, it has vast amount of 0/1 information as a model. To organise it, the information is divided into each 6 nozzles so that every 6 nozzles reads 0/1 information simultaneously. For example, only first nozzle should be opened on the first target of each nozzle, the information form is 100000 (= open/close/close/close/ close/close). That is only the first nozzle targets are used for actual tool path movement as the nozzle distances are fixed.
Tool V. 4.5 Development
Tool V. 4.5 Development
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Next we have to set real output from computational result to try higher resolution models. However, there are a few concerns with this fabrication logic. As long as the logic based on voxel system, if the model is printed horizontal direction, the connection between those drops could be weaker than just building vertical direction. If the goal is printing high resolution voxel model, the same thing with the experiment with zcorp printer would happen. Hence the voxel model need additional material to make it substantially strong.
PRINTING VOXEL
The opening timing is controlled by Arduino and Grasshopper components called pulseDo, wait and speed. Arduino can command of the length of sending signal because there is a delay time between a robot and Arduino signal. PulseDo can control certain time to open the nozzles. Wait component works for waiting time on the every single target and speed component can control the robot speed from the target to next targets. According to a few test cases, the tool path works under either Arduino timing=3s, puleDo length=0.5s, waiting time=1s, robot velocity=30mm/s, or Arduino timing=3s, puleDo length=1s, waiting time=2s, robot velocity=40mm/s. While the process is still on going, physical printing test brought good result, we could not see any con tour texture on the surface.
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PRINTING VOXEL
213 PRINTING VOXEL Printing Voxel Progress
214
Metal Casting
215 Metal Casting
Phase 7 Metal Casting
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Metal Casting
217 Metal Casting
After sand printing, metal has to be casted for rebar inside of tension network. Pouring metal in a certain place involves complex procedure to control the form of the liquid during the solidifying process. Handling metal to solidify in a certain shape is related to temperature or melting point and solid point. From the following experiment, it is understood that controlling temperature of the metal can result in various forms. Casting metal in different environment and temperatures yields different effect. Controlling these environments means controlling the results. For example, we can pour metal which is melted in low temperature into the water. Water temperature is lower than metals’ that it makes fierce respond through solidifying. Metal should be poured with increasing water level to control metal figures. At the beginning of experiment, attempt was made with only water and subsequently applied to the physical prototype by settling it in the water and pour metal liquid into the cavity within the model. In architectural industry, conventional rebars are assembled with welding or tied by metal string. In addition, although structural engineers calculate and optimise rebar arrangement by grid system, sometimes rebar location is overestimated or underestimated to arrange rebars. This method is also highly labour intensive. Therefore to overcome this issue, casting metal by Microstrata fabrication logic has an advantage against conventional method. Computational design identifies proper position without surplus or shortage for structure.
Deep Water
Shallow Water
Empty Container Low-Melt Alloy + Water Pouring In Circular Motion
Empty Container Low-Melt Alloy + Water Pouring By Directing At One Point
218 Metal Casting Material : Sand + Plaster (1:1) Binder : Water Coating : Epoxy Resin
Low-Melt Alloy Casting
219 Metal Casting Prnted Compression Model
Prnted Compression Model, Low-Melt Alloy Casted
Low-Melt Alloy Casting Model intto Water
220 Metal Casting Low-Melt Alloy Casting Model intto Water
221 Metal Casting Prnted Sand Compression Prototype Low-Melt Alloy Casted
222 Metal Casting Casting Aluminium to Piece Prototype in Foundry
223 Metal Casting Mold Piece
Aluminium Castng Process
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Metal Casting
225 Metal Casting Assembled Metal and Sand Prototype
227 Line _ Pixel
Phase 8 Line _ Pixel
Printing Prototypes Catalogue
229 Line _ Pixel
In order to demonstrate how our computational logic works together with the generation of a feasible structure, we explore a 1:1 scale prototype to be fabricated. This chunk will stand at 3 meters tall and will be fabricated using the robot. Several prototype was created as options before we come up to a decision on the final one.
Top
Back
2m
1
0.5
0
Left
Right
231 Line _ Pixel Front
a Printing Prototype Block
Line _ Pixel
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Pixelstone
235 Pixelstone
Phase 9 Pixelstone Fabrication
236 Pixelstone Vesion I
Sand deposition: automated Binder deposition: spray
Vesion II
Sand deposition: automated / manual Binder deposition: single nozzle
Vesion III
Sand deposition: manual Binder deposition: single nozzle
237 Pixelstone Vesion III_ii
Sand deposition: manual Binder deposition: valve 2 nozzles
Vesion IV
Sand deposition: automated / manual Binder deposition: valve 6 nozzles
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Pixelstone
Tool V.3.5
239 Pixelstone Tool V.3.5
Single Line Printing
240
9.1_
A R C H I T E CT U R A L S PA C E
Pixelstone
Finally we marge the logic of voxel and previous contour printing logic together. Original printing model data is point clouds from processing. We mesh it in grasshopper with actual voxel size (5 x 5 x 5 mm), which is going to the printing input model. In the toolpath script, the model is cut by plans every 5mm, according to the voxel size, to create contour outlines. From these outline curves, we additionally create offsetting curves to make the model strongly work in compression. So comprettion outlines should offset inside, on the other hand, tension outlines should go outside. In order to make the fabrication process more efficient, we removed frame model and put wooden frame manually instead. Now we manage to print 300 x 300 x 300 mm cube shape pieces. Because the previous bounding pylamid fixed our printing model size, without it the model can be bigger also saving material.
241 Pixelstone Centre Voxel Point Cloud
Points Voxelise
Contour Model
Offset Outline
Tool Path Generate Process
Simulation Print Voxel by Line
242 Pixelstone Deposite Sand
FlattenSand
243 Pixelstone Printing Contour
Printing Offset Contour
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Pixelstone
245 Pixelstone
Phase 10 Pixelstone
247 Pixelstone piece #310, 311
249 Pixelstone piece #210(Left), 310(Right)
250
Pixelstone
251 Pixelstone piece #210(Left), 310(Right)
piece # 310 (top, middle, bottom)
253 Pixelstone piece #200, 211,
piece #200, 300, 311,
piece #200,
Pixelstone
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piece #210, 310, 311
Pixelstone
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259 Architectural Scale Projection
Phase 11 Architectural Scale Projection
Reinforced Space
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Reinforced Space
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Reinforced Space
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Reinforced Space
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Reinforced Space
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Reinforced Space
Reinforced Space
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Reinforced Space
Reinforced Space
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Reinforced Space
Reinforced Space
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Reinforced Space
Reinforced Space
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Reinforced Space
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Reinforced Space
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GOTHIC SUBSTENTIAL
APPENDIX GOTHIC SUBSTENCE
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284 GOTHIC SUBSTENTIAL
G OT H I C S U B STANCE Rooted back to Gothic ontology, the first workshop by the title of “Gothic Substance� is the investigation and deep understanding of Gothic spirit. This is when the matters of high-resolutions, figural, ornamental and structural collide in a heterogenous harmony. Based on multi-objects ideology, figures unite to compose a single structure which is choreographed with respect to hierarchical relations.
GOTHIC SUBSTENTIAL
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GOTHIC SUBSTENTIAL
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GOTHIC SUBSTENTIAL
GOTHIC SUBSTENTIAL
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GOTHIC SUBSTENTIAL
Section_
GOTHIC SUBSTENTIAL
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GOTHIC SUBSTENTIAL
Plan_
GOTHIC SUBSTENTIAL
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GOTHIC SUBSTENTIAL
GOTHIC SUBSTENTIAL
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GOTHIC SUBSTENTIAL
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GOTHIC SUBSTENTIAL
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MICROSTRATA
MICROSTRATA
MICROSTRATA
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MICROSTRATA
MICROSTRATA
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304 MICROSTRATA
ACKNOWLEDGEMENT MICROSTRATA would like to express macro thanks to our amazing tutors, Manuel-Jimenez Garcia and Gilles Retsin for all the knowledge and advise we have gained during the past full year at GAD. Special thanks to Vicente Soler who has given us so much support for robotics, and to Tom Trevatt, our report tutor who guided us through the writing process. We would also like to thank all family and friends who have been supportive, to those who listen and understand, who encourage and appreciate. We thank you.
305 MICROSTRATA SYAZWAN RUSDI
MAHO AKITA
WONIL SON
FAME ORNRUJA BOONYASIT
Malaysia
Japan
Korea
Thailand
syazwan.rusdi@gmail.com
mahoakita@gmail.com
wonil.son.kr@gmail.com
fameoboonyasit@gmail.com
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MICROSTRATA
MICROSTRATA
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