Lemmy Hu

Content

02 Indorama Pavilion

04

manufacture technique

material

upcycling process

Material Workflow of Project

CONSUMER WASTE INDUSTRIAL WASTE TWISTING

WARPING

SIZING

DRAWING-IN

WEAVING ULTRASONIC WELDING

SORTING COLLECTING WINDING ULTRASONIC WELDING

WOVEN/ KNITTING

rPET GRINDING

MELTING

WINDING

BALING

OPENING NON-WOVEN

CARDING

CROSSLAPPING

NEEDLE PUNCHING

HEAT PRESS

WASHING

Non-woven Panel

rPP PELLETIZING

05

WINDING

MELTING

EXTRUDING

COOLING

PULLING

CUTTING EXTRUSION

rPETG MELTING

EXTRUDING ROBOTIC PRINTING

03

General Circular Economy Diagram recycling specifications 0-25%

shredding/washing/separating 34-60%

sorting collector 2-5%

compounding and yarning specs

0-5% heat reclycling 5-100%

extrusion non woven blow molding

0-2%

0%

land fill 30-60-100%

woven/kinitting thermal forming injection forming rotational molding

new materials made from trash 100% re-recyclable appilcation

MAC Ward

01 Concrete Fromwork

Content ｜ 01

SPINNING

Fitness Pavilion

01 PETG Concrete formawork Professional Group Project Nov.2021 – Jan.2022 Practical Design Project

Introduction As a collaboration with ROSO COOP, the project focused on using PETG, a plastic material, to form a concrete formwork instead of traditional uses of wood and aluminum. Made by a robotic arm, not only does the formwork enable a high degree of customisation, it is also more cost efficient, sustainable and recyclable. This research could be modified to be a modular sysyem.

To ensure maximum level of safety of the formwork, my role included running a precise analysis of the lateral pressure support required and performing manipulations through further adjustments in the structural design.

Exploded View

Workflow PETG female mold

ROBOTIC PRINTING

CASTING

Fixture

Overhangs

PETG male mold

Robot Workspace Printing Position

#3 rebar Formwork for forklift

DESIGN TOOL

#3 rebar Formwork for foundation Geometry Design

Opening

Printing Path

Drop 1

Supports

Formwork Static Test The lateral pressure of concrete materials is affected by temperature and the velocity of impact.

To test the maximum stress that can be borne by the formwork, the temperature was set at 20 degrees and velocity at 2.2/hr, 1.1m/hr and 0.55m/hr.

Demountable

Formworks

Analysis

Drop 2 The Drop System

male mold

1hr max stress

2hr max stress

4hr max stress

1hr max stress

2hr max stress

4hr max stress

1hr max stress fail

2hr max stress fail

4hr max stress fail

1hr max stress fail

2hr max stress fail

4hr max stress safe

female mold

without supporting

without supporting adding supporting

with supporting

finishing

Concrete Formwork ｜ 02

Type Robotic Fabrication Site Taichung, Taiwan Supervisor Shih-Yuan Wang yuan@arch.nctu.edu.tw Role Structural Analysis Detail Design & Optimization

02 HHBL Indorama Pavilion Professional Group Project Mar.2018 – July.2018 Practical Design Project

Introduction Located near Suvarnabhumi Airpot, spanning across 350 sq.m., the Indorama Pavilion was the first tension pavilion built by HHBL. The structure system of the pavilion was to be erected before the shape of the canopy was formed. Cables were inserted through the canopy, not only controlling the shape and aesthetic of the pavillion, but also avoiding water captured in-between the fabric.

The design of the cables required a precise balance between aesthetics and tension required to hold the structure against weight, force and environmental elements such as wind and rain.

Form Finding

Exploded View Indorama Pavilion ｜ 03

Type Fabric Tensile Structure of Pavilion Site Bangkok, Thailand Supervisor Jarvis Liu - jarvis.liu@miniwiz.com Role Design Assistent Structural Analysis Detail Design & Optimization

With the provided shape and size of the canopy, the structure must be optimised and the pavilion must enable maximum area of public space.

T Y P E 1

T Y P E 2

T Y P E 3

Using four supporting columns, a basic canopy shape was formed and the shaded, usable area was studied.

Two supporting columns were connected into a cross structure as an attempt to increase shaded, usable area.

The canopy was doubled, supported by cantilever beams to reduce the number of columns and increase the shaded, usable area.

cable

rPET fabric

membrane plate 1 supporting pipe main column cantilever beam anchor

membrane plate 2 membrane plate 3

Cable Tension Test The tension of the cable must be precisely calculated to avoid water being captured between the fabric. direction of cable tension

cable tension force :15300N

cable tension force :20850N

cable tension force : 23730N

Wind Simulation The simulation included analysis of wind speed and direction, using Solidworks to simulate pressure and velocity of impact, the degree of force and moment was derived.

S T E P 1

Construction Sequence

Maximum wind speed from the East : 30 km/hr

The construction was more than a simple plan of sequence.

Throughout the works, regular tightening of the cable tension was required to ensure rain water would not be captured.

wind rose

pressure distribution

velocity distribution(plan)

velocity distribution(right)

Maximum wind speed from the South : 90km/hr

wind rose

pressure distribution

velocity distribution(plan)

velocity distribution(right)

Static Simulation

S T E P 2

canopy deformation

canopy deformation

whole structure stress

whole structure stress

main columns stress

cantilever beams stress

supporting pipes stress

cables stress

membrane 2 stress

membrane 3 stress

S T E P 3

Assemble cantilever beams on the columns and cross the canopy

S T E P 4

Assemble supporting pipe between cantilever beams and columns

S T E P 5

Set up membrane plates on the canopy and assemble on beams

S T E P 6

Set up membrane plates on the canopy and assemble on anchors

3

4

connection stress

As a result of the structural simulation, we were able to derive the force of each cable followed by designing the membrane plates and each connection detail using such data.

membrane 1 stress

2 Assemble canopy on the top of columns

connection stress

Membrane Plate

S T E P 3

S T E P 2

1 Set up cables on the canopy

membrane 4 stress

S T E P 7

5

6

7 well done

Indorama Pavilion ｜ 04

With the understanding of wind force, each reaction force of the canopy was recorded.

Utilising RFEM, the structure elements and characteristics were calculated.

S T E P 1

03 MAC Ward Professional Group Project May.2020 – Mar.2021 Practical Design Project

Introduction As a response to the Covid-19 outbreak, the Fu-Jen Hospital looked to create a modular ward that is flexible and convertible according to varying needs while being able to assemble at a timely and effortless manner.We participated in the design using recycled aluminum (rAluminum) as the structure, including beams, columns, walls and floors. The design incorporated PP extrusion recycled from masks to create a negative pressure ward that also holds all the equipments within the space. Each component was carefully designed and reviewed through static and dynamic analysis.

The design presented astonishing results with the ward assembly taking less than 10 hours to be completed.

Exploded View

Whole System Static Test rAluminum main beam

rAluminum sub-beam

I were able to perform static test on the entire system at 1.8 tons (the required impact tolerance level of medical equipment ).

rAluminum ceiling panel

Structure System Connection Static Test The connections were made by steel, joint with each aluminum extrusion. The yield strength of steel is stronger than aluminum at 250MPA.

rAluminum wall panel

connection 1 stress 51.5>250MPA (safe)

ton

1.8

rAluminum sub-column rAluminum main column Electrical channel

connection 2 stress 51.5>250MPA (safe)

Beam and Column System Static Test Several structures and sections were built to study the feasibility of recycled aluminum as a main material.

As welding could not be performed on aluminum, all connections were joint using steel plates. The stress test was performed by separating the structure into four columns supporting beams.

300kg of force was placed in the middle of each beam to identify the appropriate system.

section 1 stress: 148>145 (fail)

section 3 stress: 105>145 (pass)

section 2 stress: 112>145 (pass)

type 1 structure deformation Type 1

type 3 structure stress

type 2 structure stress

type 1 structure stress

type 2 structure deformation Type 2

type 4 structure stress section 4 stress: 98.7>145 (safe)

type 3 structure deformation Type 3

type 4 structure deformation Type 4

MAC Ward ｜ 05

Type Modular ward system Site Taipei, Taiwan Supervisor Jose Lopez - jose.lopez@miniwiz.com Role Design Structural Analysis Detail Design & Optimization

Modular System Wind Force Analysis

Exploded View

The modular system consists of several elements including rAluminum wall panels, rAluminum extrusion, PP extrusion and TPV extrusion. Using different levels of wind speed (between lv6-17), each element of the system was tested and data was derived as shown below.

Main rAluminum column rAluminum extrusion T-type nut

Aluminum Wall Panel Static Test

TPV extrusion

Wind level 6

rAluminum wall panel is recycled by aluminum formwork.

Wind level 11

Wind level 15

wind speed: 13.8m/s

wind speed: 32.6m/s

wind speed: 50.9m/s

wind speed: 62m/s

wind force: 23kg/m2

wind force: 128kg/m2

wind force: 312kg/m2

wind force: 500kg/m2

stress : 1.99<145 (safe)

stress : 11.1<145 (safe)

stress : 26.9<145 (safe)

stress : 43.2<145 (safe)

wall panel stress

wall panel stress

wall panel stress

rAluminum wall panel

wall panel stress

PP Extrusion Impact Test

Wind level 6

Wind level 11

Wind level 15

Wind level 17

wind speed: 32.6m/s

wind speed: 50.9m/s

wind speed: 62m/s

wind force: 23kg/m2

wind force: 128kg/m2

wind force: 312kg/m2

wind force: 500kg/m2

stress : 4.6<145 (safe)

stress : 25.2<145 (safe)

stress : 59<145 (safe)

stress : 98.6<145 (safe)

extrusion stress

extrusion stress

extrusion stress

PP Extrusion Static Test

start point 0.85<27.6 (safe)

point 2 21.4<27.6 (safe)

point 3 23.9<27.6 (safe)

end point 9.38<27.6 (safe)

Screw on PP Extrusion Static Test Wind level 6

rPP extrusion is recycled by mask.

Testing buckling when PP extrusion puts into aluminum extrusion.

MAC Ward ｜ 06

wind speed: 13.8m/s

extrusion stress

PP extrusion TPV extrusion

Aluminum Extrusion Static Test

rAluminum extrusion is recycled by aluminum formwork.

M5 screw

Wind level 17

Wind level 11

Wind level 15

Wind level 17

wind speed: 13.8m/s

wind speed: 32.6m/s

wind speed: 50.9m/s

wind speed: 62m/s

wind force: 23kg/m2

wind force: 128kg/m2

wind force: 312kg/m2

wind force: 500kg/m2

stress : 1.68<27.6 (safe) PP extrusion stress

stress : 9.2<27.6 (safe)

stress : 21.5<27.6 (pass)

stress : 36<27.6 (fail)

PP extrusion stress

PP extrusion stress

PP extrusion stress

Testing how much weight that each screw can hold.

Maximun weight is 15kg per screw.

5kg 109<250(safe)

10kg 148<250 (safe)

15kg 220<250 (safe)

20kg 291>250 (fail)

04 HHBL Fitness Pavilion Professional Group Project Mar.2019 – Sep.2019 Practical Design Project Form Finding Due to the form of structure is symmetry, I create several types to check which one is most stable to hold the canopy. Trying to find the efficient canopy to avoid puddle and collect rainwater to the center of pavilion.

Fitness Pavilion ｜ 07

Type Fabric Tensile Structure of Pavilion Site Bangkok, Thailand Supervisor Jarvis Liu - jarvis.liu@miniwiz.com Role Leading Design Structural Analysis Detail Design & Optimization Introduction Located near Suvarnabhumi Airport, Bangkok, The Fitness Pavilion was the second tension Pavilion built by HHBL, spanning across 400 sq.m..

The project requested a light weight structure that provides maximum public space for fitness activities.

Our design proposed a centralised structural support, minimising the space occupied by beams.

The geometric canopy design provides a lighter structure and eliminates water accumulation. A 36 sq.m. planter area was placed in the middle of the pavilion for aesthetics, achieving a 364 sq.m. space for the public to use.

1 2 3 4 5 6 7 8 9 10 11 12 1 type 1 model 2 type 2 model 3 type 3 model 4 type 4 model 5 type 1 canopy deformation 6 type 2 canopy deformation 7 type 3 canopy deformation 8 type 4 canopy deformation 9 type 1 structure stress 10 type 2 structure stress 11 type 3 structure stress 12 type 4 structure stress

Tree-like main column structure was used to achieve a lightweight design.

The canopy was separated into two layers and foundations were centralised to provide more space for public use.

Type 1

Type 2

The top structure and the canopy were revised to achieve mechanical equilibrium.

Type 3

The whole structure was simplified and the canopies were revised as one layer, avoiding water being captured on the fabric.

Type 4

Wind Simulation

Member Simulation

Researching the data of wind speed and direction in Bangkok, and using Solidworks to simulate the value of pressure and velocity. With the calculation of wind pressure, the value of force and moment on canopy come out.

When getting the result of wind force, we can know each reaction force of the canopy. After that, utilising RFEM to calculate the structure members, including columns, beams and cables and optimize the detail of each connection.

pressure distribution

cantilever beam

membrane 1

main columns

membrane 2

lower ring

upper ring

supporting pipe stress

cantilever beam stress

membrane 1 stress

main columns stress

membrane 2 stress

lower ring stress

upper ring stress

supporting pipe deformation

cantilever beam deformation

membrane 1 deformation

main columns deformation

membrane 2 deformation

lower ring deformation

upper ring deformation

velocity distribution(right)

canopy deformation

Construction Sequence Making the structure system first, and then assemble canopy with proper tension.

whole structure stress

Fitness Pavilion ｜ 08

supporting pipe velocity distribution(plan)

05 Ceiling/Wall System Non-woven Panel Professional Group Project Jan.2019 – May.2019 Practical Design Project

Introduction As a R&D project by Miniwiz, the non-woven cross panel is a building material of ceilings and walls. The material is made of felt, which is soft by nature, but becomes hard when it experience heat pressing. With the heat press process, we were able to change the form of felt, leading the team to design molds of panels that can shape the material flexibly. The material assembly was a challenge to overcome, as well as its characteristics. Several revisions were made based on the physical property, fabrication and the assembly of the material. Today, this panel is produced in many interior projects of Miniwiz's.

Manufacture Process

The nature of non-woven felt enables the hard panels to form a structure that supports itself, reducing material wastes and simplifying assembly.

Yarn goes warp way and weft way on the loom, made by interlacing threads at right angles to one another. Yarn goes warp way and weft way on the loom, made by interlacing threads at right angles to one another.

A rectangular panel could not support its weight in a ceiling system.

Step 1

A stepped structure design enabled more strength and further shape adjustments made the panels connectible.

Step 2

Spray a silver ion coating as the finishing to give the performance of anti-microbial and viral resistance.

Collected bottles will be cut into small pieces, wash and filter several times, then become the rPET flakes.

SHREDDER Turn the rPET flakes into liquid and extrude to form filaments yarn then cut into staple fiber.

SPINNING Size reduced tufts are split into fibers then unravelled, aerated & paralellized by rollers.

SPRAY COATING

WEB CONSOLIDATION Make a cutting mold to split felt outline into a product.

DIE CUTTING One side of the boarder was stretched to connect with another panel, forming the joint area.

Step 3

Mold Production

The panels were assembled repeating step 3, forming the entire ceiling system.

Step 4

NEEDLE PUNCHING

Static Simulation Weight tests were performed to incorporate light bulbs on the panel.

A flat aluminum panel mold was created to heat press the non-woven felt.

A wooden, curved mold was made to heat press the non-woven felt.

Needles are launched across the batt to create a 3D felt web which fibers entangled vertically

Several felt layers are heat pressed together with a 3D shape mold to form a sheet of panel.

HEAT PRESS

1 2 3 4 1 single panel stress 2 single panel deformation 3 ceiling system stress 4 ceiling system deformation

A system made of 6 panels were hung onto the ceiling while each connection point was weight tested and analysed.

Non-woven Panel ｜ 09

Type Interior material R&D Site Taipei, Taiwan Supervisor Jose Lopez - jose.lopez@miniwiz.com Role Design Structural Analysis Detail Design & Optimization

Form Finding