Digital Design & Fabrication Journal

Architectural Design Studio 2 (Construction) (Sem 1)

Digital Design & Fabrication

Charlotte Mwaba

Contents

Introduction............................................................... ii Digital Experimentation 01....................................... 1 Digital Sketching................................................................................................. 2

Digital Fabrication & Prototyping 01....................... 5 Digital Modelling, Fabrication & Prototyping................................................... 6 Construction of Prototype................................................................................ 10

Digital Experimentation 02..................................... 15 Digital Sketching & Modelling: Canopy ........................................................ 16 Digital Sketching & Modelling: Gridshells....................................................... 18 Digital Sketching & Modelling: Surface & Structure...................................... 20 Digital Sketching & Modelling: Form Finding................................................. 22 Digital Sketching & Modelling: Parametric Walls.......................................... 24

Digital Fabrication & Prototyping 02a.................. 29 Precedent Study .............................................................................................. 30 Digital Modelling, Fabrication & Prototyping................................................. 40

Digital Fabrication & Prototyping 02b.................. 51 Design Concept................................................................................................ 52 Digital Modelling, Fabrication & Prototyping................................................. 54

Digital Experimentation 03..................................... 67 Digital Modelling: Designing for Cable Ties.................................................... 68 Digital Modelling: Form Finiding & Cable Tie Iterations................................ 70

Appendix ..................................................................iii

i

Introduction Tectonic systems & prototyping in architecture Prototypes allow designers to investigate design ideas and explore the structural performance and aesthetic possibilities of materials and construction techniques.

The following is a collection of digital and physical prototyping of materials and methods.

ii

Charlotte Mwaba | 2018

Digital Experimentation 01 Initial explorations of parametric modelling techniques Studio | Ideation

1

Digital Sketching Working from a group of lines and curves to develop unique surfaces, using basic techniques in Rhino and Grasshopper.

2

Further outcomes from using the same techniques to create three dimensional void forms. Then transforming the surafce into triangular panels.

Iteration 1

3

Digital Fabrication & Prototyping 01 Void form with triangulated panellling Studio | Project

5

Digital Modelling, Fabrication & Prototyping Iteration 2: Cylindrical model and panelled surface.

Chosen iteration for physical prototyping.

6

7

The chosen digital model is prepared for laser cutting. Each panel from the model is organised into sequenced cut sheets, ready for fabrication.

8

20

40

60

80

100

120

19

39

59

79

99

119

18

38

58

78

98

118

17

37

57

77

97

117

16

36

56

76

96

116

15

35

55

75

95

115

14

34

54

74

94

114

13

33

53

73

93

113

12

32

52

72

92

112

132

11

31

51

71

91

111

131

10

30

50

70

90

110

130

9

29

49

69

89

109

129

8

28

48

68

88

108

128

7

27

47

67

87

107

127

6

26

46

66

86

106

126

5

25

45

65

85

105

125

4

24

44

64

84

104

124

3

23

43

63

83

103

123

2

22

42

62

82

102

122

1

21

41

61

81

101

121

9

Construction of Prototype Construction involved laser cutting each set of panels. Then using tape and hotglue, assembling the numbered panels in sequence (i.e. 1-10, 11-20, 21-30...). Then finally, building up the entire form using the digital model as a guide for construction.

10

11

The final outcome and prototype.

12

13

Digital Experimentation 02 Further explorations of parametric modelling techniques Studio | Ideation

15

Digital Sketching & Modelling: Canopy Exploring techniques for modelling a typical canopy or pavillion structure.

Iteration 1

16

Iteration 2

17

Digital Sketching & Modelling: Gridshells Experimenting with different geometries and the corresponding grid structure overlaid onto the surface of organic shapes.

Iteration 1

Iteration 2

18

Iteration 3

19

Digital Sketching & Modelling: Surface & Structure Using wave-like curves as the base geometry to form an organic structure.

Iteration 1

Iteration 2

20

21

Digital Sketching & Modelling: Form Finding Further exploring the ‘wave-like’ shape, with solid shapes to form the curved surface shape.

Iterations

22

23

Digital Sketching & Modelling: Parametric Walls Wall types: the hexagonal shape is an effective use of materials and provides structural integrity.

Iteration 1

24

Wall types: exploring how to tranform a base wall shape to create different effects.

Iteration 2

Iteration 3

25

Iteration 4

Iteration 5

26

Iteration 6

Iteration 7

27

Digital Fabrication & Prototyping 02a Generative design concept for a pavillion structure Studio | Project

29

Precedent Study BHP BILLITON CONFLUENCE PARK RIVER PAVILLION

30

CONSTRUCTION PROCESS: STEP 1 CNC MILLING THE MALE MOULDS & FORMING THE FEMALE MOULDS

STEP 3 CASTING THE CONCRETE PANELS

STEP 4 TRANSPORTING AND ASSEMBLING PAVILLION

31

CONFLUENCE PARK RIVER PAVILLION TESSOLATION PATTERN BASED GENERATIVE DESIGN

32

Digital Modelling USING THE SAME WORKFLOW TO EXPLORE AND EXPERIMENT WITH DIFFERENT TESSELLATION PATTERNS Iteration 1

33

Iteration 2

34

Iteration 3

35

Iteration 4

36

Chosen tessalation pattern and design

37

Precedent Study - Concrete Surface Texture PROJECT: Edithvale Wetlands Discovery Centre in Edithvale, Victoria ARCHITECT: Minifie van Schaik (MVS) Architects This project showcases the potential of precast concrete panel construction.

38

The pattern on the faรงade panels was digitally created patterning was milled from laminated MDF using a 5-axis CNC router machine.

The timber was then coated with epoxy and tooling resin ready for casting using GRC concrete.

39

Digital Modelling, Fabrication & Prototyping The following are digital experiments with different black and white patterns, and the resulting surface textures created.

40

41

42

Casting Concrete Using prototypes to test materials for moulds to cast in. Also, testing the way concrete takes on different surface indentations.

43

Prototype Fabrication STEP 1 CNC FILE PREPERATION FOR THE MALE MOULD

STEP 4 VACUM FORMING FEMALE MOULD

STEP 6 POURING A PLASTER PROTOTYPE

44

STEP 2 MILLING THE MOULD

STEP 3 PREPARING THE MALE MOULD FOR VACUM FORMING

STEP 5 VACUM FORMING FEMALE MOULD

STEP 7 CASTING PIGMENTED CONCRETE INITIAL PROTOTYPE

45

Final Design CONCRETE PAVILLION MODEL DESIGN WITH SURFACE TEXTURE

46

47

ELEVATION 1

ELEVATION 3

48

ELEVATION 2

ELEVATION 4

49

Digital Fabrication & Prototyping 02b Generative design development for a pavillion structure Studio | Project

51

Design Concept The idea of urban vs natural. A juxtaposition of man-made materilas, like concrete and natural elements, like plants and water.

52

Nature leaves an imprint on what is man-made, especially to the exposed surface of concrete, wether just poured or left for some time.

SURFACE CONCEPT

53

Digital Modelling, Fabrication & Prototyping CONCRETE PAVILLION DESIGN

1:00

54

DIGITAL FABRICATION - SIMULATE HOW RAINWATER FLOWS OVER THE PANEL FORM

FORM

PANEL A

PANEL B, C

55

Concrete Surface Digital Prototype Further development of surface patterns and the resulting textures on a curved surface for prototyping

56

57

Simulation of how water or rain would fall over the resulting surface texture when applied over to the form.

58

59

Prototype Fabrication Using the prototyping process established in stage 1 of design development, the mould was CNC milled, vaccum formed then cast with plaster.

FINAL PROTOTYPE

60

Prototypes used to test what surface would encourage natural growth to concrete.

Also, to investigate the suitability of re-using materials like bubblewrap and styrofoam in the mold making process. This may have a positive impact on reducing widespread plasitc pollution in the environment.

Conctere prototypes allowed to weather in the natural elements.

61

Final Design CONCRETE PAVILLION MODEL DESIGN WITH SURFACE TEXTURE

1:00

62

Initial visualisation

Projected visualisation

63

3D printied model of pavillion design, with indicative ‘moss’ growth.

64

Complete collection of prototypes.

65

Digital Experimentation 03 Further explorations of parametric modelling techniques Studio | Ideation

67

Digital Modelling: Designing for Cable Ties First modelling a base form to define the shape of the model. Then applying triangular panels to the surface. This allows the transforming of the surface into cable tie geometry.

Iteration 1

68

69

Digital Modelling: Form Finiding & Cable Tie Iterations

Iteration 2

Iteration 3

70

71

Iteration 4

72

73

Appendix Digital Experimentation 02........................................................... 15-27 Digital Sketching & Modelling: Canopy ........................................................ 16 Reference: https://youtu.be/qHcztuFtwcc Published 18.05.2016

Digital Sketching & Modelling: Surface & Structure...................................... 20 Reference: https://youtu.be/rOPjyzgfRCU Published 08.05.2014

Digital Sketching & Modelling: Parametric Walls.......................................... 24 Reference: Canhui Chen Reference: https://youtu.be/y7gJ0Gz6QR4 Published 20.02.2017 Reference: https://youtu.be/8TFrz2eWyB0 Published 22.04.2013

Digital Fabrication & Prototyping 02a........................................ 29-46 Digital Fabrication & Prototyping 02b........................................ 51-62 Group project participants: Jacinta Princi, Nathan Flynn

Digital Experimentation 03........................................................... 67-70 Reference: Canhui Chen

Charlotte Mwaba | 2018 iii