3M futureLAB 2013

3M futureLAB

Additive Ecologies: Apartment Living in the Age of 3D-Printing

Mitchell Hattersley - U0856059

Contents 01

3D Printing in Architecture Designing a 20m2 Microapartment

02

The Nylon Apartment

3D Printing a 5.3m2 Microapartment

03

The Voronoi Mug

How Can 3D Printing Improve a Mug Design?

04

Small Transportable Living 3D Printing a Microapartment

3D Printing in Architecture Designing a 20m2 Microapartment

Precedents: 3D Printing

The existing ideas for construction using 3D printing provide diferent ideas and uses that will provide some inspiration to my design.

Softkill aims to create algorithms that help to minimise the usage of materials within a generated design, using a bone structure as inspiration.

Foster and others have suggested 3D printing using the materials that are available on site.

This could allow construction to take place almost anywhere in the world and some also out of this world, such as the moon.

Precedents: Interior

The best small apartments give the illusion that they are much bigger than they actually are.

Humans tend to dislike small and cramped spaces and the claustrophobic impressions that they create.

Here are some precedents and methods that look at how to transform a small space into a functional and usable space, as this is the most important aspect to consider when designing a small apartment; will the user be able to live in it comfortably?

Natural light plays a big part in making a small space appear much larger. This combined with light colours and reflective surfaces really helps to enhance a small space and create the illusion of a much bigger and grander apartment. Many of the precedents I looked at contained plenty of windows to let in natural light and had crisp white reflective surfaces. Natural materials such as timber also provide a nice soft contrast.

The height of the space is another important feature, with most small apartments being one and a half storeys high. This allows for the illusion of a double heighted space in some areas, with a raised mezzanine area providing a cosy and functional sleeping area. By raising the sleeping area, it helps to really minimise the footprint of the apartment.

Precedents: Conceptual

I began by looking at nature for answers, researching how bees effectively 3d print their homes and how structurally strong and efficient the honeycomb form is.

I continued my research into honeycomb structures and came across designs generated by voronoi algorithms and the structural integrity that these provide.

Using a honeycomb or voronoi structure will allow the frame thickness to be much thinner than traditional steel or timber framework. The structure could also be optimised to use the least amount of material possible.

Another inspiration after looking at bees is to use natural materials, such as soil and sand.

Design: Isometric

My idea is to 3d print the exterior structure and the mezzanine, ready for cladding, insulation and servicing to be added traditionally. The benefit of 3d printing is that the structure can be fibrous to minimise the use of materials, and the honeycomb structure adds strength and efficiency.

The cube form of the apartment will allow spacial efficiency on the interior, as well as allowing the aggregation of the form to be stacked.

Groundfloor Plan

The groundfloor features a complete kitchen and wetroom bathroom underneath the bedroom mezzanine. Taking a step up from this leads you into the one and a half storey heighted lounge with a large window letting plenty of natural light into the whole apartment. This could also open out onto a balcony depending on where the building is situated.

The lounge can contain a pull out sofa and underneath the stairs there is room for more seating or storage could be there with a pull out desk and drawers.

In a small apartment layout like this it is all about maximising space and functionality.

Mezzanine Plan

Upstairs allows for 2 metres of height and manages to fit a double bedroom and a small office space in. This space is open to the rest of the flat, allowing plenty of natural light in from the large window.

3D Perspective

A 3D perspective view of the apartment, showing the 2 steps up from the kitchen into the lounge to differentiate the interior spaces. The apartment manages to feature a full kitchen, a lounge and a sizeable mezzanine with bedroom and office.

3D Printed Model

The 1:50 printed model shows the structural element that will be printed, before insulation, services and cladding is added traditionally.

Precedents: Aggregation

The functional form of the cube will allow for easy aggregation of the apartments to form blocks of flats, allowing multiple units to be printed and stacked efficiently.

The Nylon Apartment 3D Printing a 5.3m2 Microapartment

Precedents

For the next stage we were put into groups of three based on who had similar concepts and were given the task of developing a design by the end of the week. Our group decided to look at fibrous structures, raised sleeping pods and built in storage techniques.

Initial Design

For our initial design we started off with one of the group members designs that aimed to provide a double heighted living space, a hanging sleeping pod and a raised bathroom. The form also allowed for multiple units to stack.

Development

The initial brief for the project was then changed with the intention of reducing the floor area. To accommodate this change the development of the project led to the raised area of the design becoming the sleeping area, and the toilet/wet room area being placed wthin the poche of the structure.

Development Section

A section showing the raised sleeping area and the sinous built in printed stairs. The structure will be the fibrus exoskeleton.

Development Render

Developmental render for the interim review to show the view of the sleeping area from the kitchen. The living space would be the stepped area between these two spaces.

Developmental Render

Render showing the view from the raised sleeping area looking down into the living and kitchen area.

Developing the Skin & Structure For the skin we looked into new materials and technology that could be incorporated and hopefully 3D printed into the design. We discovered research into the application of 3D printing Aerogel which has very high insulative properties whilst also remaining translucent to allow plenty of natural light to pass through.

For the structure we investigated into using ABS and nylon, with the potential of using Carbon Fiber after receiving a lecture on the research going into printing it.

Aggregation

Part of the brief stated that we had to find a location and purpose for our designs. The form of our design aggregated allowed the possibility of it being stacked to create an arched type structure that could maybe form a bridge or could potentially be 3D printed into the structure of existing bridges.

Further Development

The brief was changed and the floor area reduced even further, down to 5.3m2. To accommodate this change we researched into 3D printing nylon and the different composites available. The properties of these compounds would allow us to print a stiff composite for the strutural elements and a different compound with elasticity for the skin of the sleeping pod.

This would allow the skin to stretch and would make the pod similar to that of a hammock.

The bathroom is again located within the poche to save space.

Further Development

To further save space, the steps up to the bed also double up as seating and a desk/table.

The material underneath will be the stretchable compound so you climb into the seat to use it, with room for your legs underneath the sleeping hammock.

Seat & Mattress Development

Next we decided to focus our research on how to 3D print and integrate a spring or cushion system into the seating and mattress area. We first looked at a system of pins sat in ball joints, however this wouldn’t provide the comfort that we wanted to achieve.

Spring Development

We developed a spring system that could be 3D printed into a seat or mattress design and would provide a cushioning effect, adding comfort and functionality to the microapartment design.

Design Render

A Render showing the interior of our 5.3m2 microapartment. The toilet is located inside of the poche and the material of the doorway will be stretchable nylon. The idea is that you climb into the bathroom, climb into the seat, climb into the hammock, changing the way we interact with space.

The Voronoi Mug

How Can 3D Printing Improve a Mug Design?

Problems with Existing Mugs

The problems with existing typical mugs are threefold. Firstly, when used without a coaster they will often leave a nasty ‘mug ring’ on your coffee table or surface.

Another problem is that the heat from the hot drinks poured into them often makes them hard to handle without hurting yourself.

Finally, the weakest point of a mug is its handle and these are often the first thing to break off.

Existing Solutions

People have attempted to overcome these problems, however they seem to only focus on one problem at a time.

What happens if you put the coaster solution together with solutions to fix breakages and the mug being too hot to touch?

The Voronoi Mug

The Voronoi mug provides a solution to all three problems. It features a beautiful coffee sleeve on the exterior that allows you to pick the mug up no matter what drink is inside of it. This sleeve also means that there is no handle present to provide a weak area prone to breakages.

It also features a built in coaster so that you can sit it down wherever without worrying about leaving nasty coffee rings.

The Voronoi Mug

The Voronoi mug works by seperating the mug from the users hand by use of the sleeve. This sleeve is then connected to the mug via bridges that are angled downwards to ensure any spillage from the mug runs down to the built-in coaster.

The bridges also suspend the mug in space so that any spillages run down the mug and drop onto the coaster, protecting the surface that you place the mug upon.

3D Printed Model

Here is a photograph of the mug successfully 3D printed.

Small Transportable Living 3D Printing a Microapartment

Rural Depopulation

Increased Spatial Efficiency

Micro Living Demand

The relevance of micro-living within contemporary society arrives as a result of the rise of city living in dense environments. With a reported 50% of young people now living alone in our cities, the desire for excessive space has transformed towards a will for efficient, functional living.

25% Families

50% Of People Live Alone

25% Couples

Cost Effective

The Target Group

Young Professionals

1990

2013

20-35

Work Go Out Home ...

Work Exercise Network Go Out Home

The proposal is aimed to cater for student and young professionals. Its is an increasing trend that members of such a target group are spending less time in the home as a result of a competitive working and social lifestyle. In addition, the cost advantages possible in efficient living conjure an attractive lifestyle for people new to professional life.

Refs: http://www.domusweb.it/en/ architecture/2013/06/13/renzo_piano_diogene.html Refs: http://www.vitra.com/en-gb/magazine/details/ diogene

Diogene

Renzo Piano Diogene is a 2000mm squared box with a pitched roof, providing what Piano describes are primitive and the idea of basic shelter. It is self contained with all servicing designed into its envelope and necessary rigging for being crane lifted to any location desired.

It provides all that is necessary for living; a bio toilet and shower, sleeping area and small kitchen space.

Our Response: This project addresses the walking through the bathroom issue we found with the M-ch, with a small separate facilities to the back. The independent nature of the self contained design gives many opportunity and demonstrated micro engineering at its best.

With the design intent being very much focused on primitive and basic living, everything feels overly clean and sterile the luxury we all desire, no matter how big our living space, is not for filled. The space is also lacking in character in some respects it feels very much like a caravan.

Refs: Images and plans obtained from Horden Cherry Lee Architects Ltd directly

M-ch

Micro Compact Home The M-ch is a joint venture between Richard Horden and Munich Technical Institute, sponsored by O2 Germany. The project was to design micro apartments that are self contained.

We were able to visit these compact living solutions, therefore able to critically analysis the way it is designed and its sucesses.

5

Our Response: Being able to have friends round for dinner is very important, storage is the most important thing in compact living if it is not adressed correctly the space is always clutted and becomes less useable, flexible living and adaptation is very important,changing levels gives the feeling of additional space.

The one key negative we all agreed on, was entering through a bathroom that is not closeable, isnt very nice. Also the project is designed very much for the functions of micro living, with lesser importance on architectural beauty.

Dimentions 2650mm3 9

The Essentials

Expanding The Typology Integrated Multimedia Traditionally, successful micro design is achieved through stripping back to the bare living essentials. However, with connective technology now transforming our daily lives, our proposal looks to improve the typology by integrating multimedia as a main focal point for the experience.

1 2

3

4

5

Ground Floor Plan 1:10

In reaction to the additive manufacturing process, the internal approach is organic, allowing a number of everyday functions to be programmed into fixed furniture. Entrance from the rear corner immediately orientates the user towards the projected screen; a predominant conceptual feature that directed much of the planning and organisation

7

6

8

1 - Closet Door 2 - W/C 3 - Column with Integrated Ladders 4 - Folding Table 5 - Sink with integrated Bath 6 - Free Work Space 7 - Secondery Door 8 - Projection Screen 9 - Rainwater Collection

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5 1

6

2

6

3

Mezzanine Floor Plan 1:10

In order to separate the bed from other functions within the same volume, the bed is elevated. Access is achieved by a fold-away ladder, from which the bed becomes the optimum viewing point for the projected screen.

The projector is embedded within the bed structure in order to provide a central, concealed location

4

1 - Bed 2 - Integrated Projector 3 - Column with Integrated Ladders 4 - Projection Screen 5 - Wall Storage 6 - Bed Pockets

1

2

3

Longitudinal Section 1:16

The main light source for the building takes place through a large opening at the upper level. The domed form continually focusses the user towards the projected screen, thus dictating the use of the space. In order fully utilise the volume, the floor surface is elevated, allowing for services and storage below

4

6

5

1 2 3 4

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Bed Integrated Projector Projection Screen Programmable Work Surface 5 - Fold Out Table 6 - Fold Out Storage

1

Transverse Section 1:16

2

As a response to trends in micro design that strip away luxury in order to save space, the kitchen work surface has been designed as a moveable plane, concealing a soaking tub.

Whilst allowing all the required water services to be zoned in one place, this location is also poignant as the screen and isolated views out are visible, rather than hiding them away within the bathroom area

3

5

6

4

1 - Integrated Projector 2 - Column With Integrated Ladders 3 - Removable Kitchen Sink 4 - Hidden Soaking Tub 5 - Refridgereator 6 - Floor Storage

Faรงade Study

Filtration faรงade:

To collect rain water whilst filtering large particles such as leaves and reducing the fall of snow onto passers by. The penetration of light through this surface maybe challenging

Triangulated Barnacles:

From a distance the surface will appear smooth and non texture yet on approach the surface will develop a textured dimension. At night the faรงade will appear light in spots

Button Stubble:

A compliment to the Vorarlberger Landesmuseum, Bregenz. A small button surface with similar thought process with a distance smooth exterior with a texture appearing on approach

Natural Barnacles: Further exploration into the barnacle design, looking at how in nature the barnacles would reduce on convex surface and collect on the concave zones. They are of a more natural formation less angular

Experiential and functional faรงade experiments, for application to the corrugated surface.

Exploring the ideas of water collection, light on the surface day and night and changing textures.

Edouard Francois: Tower Flower.

Heatherwick Studio: Shanghai-Expo.

This model was the first point of conversation for the proposal of hair on the façade. François uses plant life to generate the hair effect on his finished projects. To embed the beauty of nature in the city.

Although the distant appearance is of hair, in actual fact each is a perspex funnel with a single seed embed, the carry light into the space.

Refs: http://www.designboom.com/cms/images/rid10/mod04. jpg http://www.archiscene.net/wp-content/uploads/2011/08/ UK-Pavilion-Expo-2010-by-Heatherwick-Studio01.jpg

External Façade - Hair Sample 1 Fixed single hairs approximately 8mm apart and 70mm in length

Sample 2

Sample 3

Sample 4

4 hair sets spaces more evenly, approx 15mm apart

Much shorter hairs with inner tubes to take the heat collected to the surface and funnel light to the skin

Close spaced hairs that move in a ball baring system for flexibility in the wind

Each designed hair has its own individual moving point inside the surface. In theory the printer will print to 0.5mm which is how I designed the hairs however in the test model to the right you can see working to that smaller a tolerance doesn’t always succeed.

Going back to original precedents, the rubber house had qualities that made the threshold and light sources ambiguous. Applying hair to the façade of the micro apartment will give the opportunity for the form to be fluid, changing with the wind and weather conditions. The form, thresholds and light sources of the building are obscured by the hair form.

This is also the technical possibility of the hairs providing insulation properties.

Sea Shell

Seashells grow from the bottom up, or by adding material at the margins. Since their exoskeleton is not shed, molluscan shells must enlarge to accommodate body growth. This pattern of growth results in three distinct shell layers: an outer proteinaceous periosteum (uncalcified), a prismatic layer (calcified) and an inner pearly layer of nacre (calcified).

Cacti Cacti create ribes in order to store water for long periods of time. Typically the deeper the rib the more water it depends on surviving. These large storage tanks allow the cactus to survive for month with out water.

+

Form Generation

The result is a combined bio-memetic morphology of hte two organic sysetms. One the structural shell which resists both lateral load and optimized the the small space and the cacti system which embedds the system within the wall.

Thermal “Bridge”

This system is based on the water tight structural organization of turtle shells. It’s design is for hi impact forces on its shell. These bridges create localized support while at the same time mainting a lightweight structure. This is system iworks well with the high pressure impacting on the wall by the vaccum wall.

4mm

40mm

Thermal Bone Structure

This sysytem bio-mimcs a typcial bone structure. It creates a light weight optimized porousity to maintian strucutural integirty for high impact forces while at the same time reducing the amount of material needed.

Because of it its cellurar nature it also acts as an inusalative barrier.

4mm

40mm

Thermal Bale Wall

This system is based of a tradtitional straw bale construction method. The cellular organization of the tubes creates a dense packing of space inhibiting exterior conidition to pass easily through the skin. Because of the water tight condition of TPU the exterior tubing can be exposed allowing the insulative system to be expressed on the exterior.

4mm

40mm

Model for ‘U’ Value Calculation

Thermal Calculations

As a result of experimental nature of 3D printing and structural efficiency, a number of calculations were set up to determine how the thermal capacity would be effected

Heat Resistence Behaviour

Rayliegh Chart

Assumptions And Conclusions

• Max. temperature difference between the • • • •

wall and air is 60 K Structure inside the wall simplified as a cylinder Kinematic viscosity and Prandl Number dependent on air No free convection occurring within a large temperature span U value of less than 0.1 W/m^2K

Conclusions • Maximal diameter of inner tubes is 11cm

‘U’ Value for different Materials and Temperatures

before the free convection with extreme conditions occurs • The goal of achieving the U-Value below the A Class Standard Efficiency level of 1 W/ m^2K • The structural calculations show that the material area fraction of 20% is achievable.

Solar Energy

Windows and Doors

Heat emission trough: • Human body • Light • Electrical units • Heating (heat load

Walls

Heating load / Technical

Heating load = heat out + heat in Building class

Others (pipes, ventilation,...)

• • • •

Ground

Build befor 1995 = 100-150 W/m2 Build after 1995 = 50-100 W/m2 Building class EnEV 2002 = 30-50 W/m2 Low energy houses = 10-30 W/m2

 Thermal conductivity = 0,05-0,1W/mK Pressure

Thermal Conductivity

Open-Cell Plastic Foams

0.5

0.008

Micro Fiber Material

1

0.004

Without Support Structure

1013

0.026

Without Support Structure

800

0.02

Without Support Structure

200

0.016

Type Of Support Structure

Mbar

W/(mK)

Finite element of the wall

External Dimentions

Vacuum Test

Heat transfer test

34.45mm 110mm

1

95.6mm

2

150mm

Vacuum Insulation Test

Part was designed for the production with laser sintering machine Formiga P100 from EOS (material PA2200)

Support Structure

5mm

3

3mm

1 - Value connection Inlet/ Outlet 2 - Test For Light Transmission 3 - Grid Support Structure

Test Bench / Process

Pressure gauge

Vacuum pump Test Object

Results

• • • •

Pressure in the beginning: 934 mbar Minimal possible pressure: 0,6 mbar Pressure after 10 minutes: 2,1 mbar Pressure after remove the connection between pump and test object: 132 mbar • Pressure after 1 hour: 153 mbar • Pressure after 4 hours: 189 mbar • Pressure after 8 hours: 293 mbar Possible reasons for pressure rise are leaks in Connections Valves

The Experiment

http://ifitshipitshere.blogspot.de/2010/01/hardboiled-housing-blob-vb3-by-dvma.html http://www.toxel.com/inspiration/2010/02/28/curtain-door-made-from-wood/

Gradual Transition

Integrated Storage

Conceptual Approach

Due to the spatial restrictions of the micro-apartment design, we felt that it was important to utilise the space taken from the opening in order to diffuse its function from solely being an entry or exit point when not in use. Rather than entering directly into a wet room like typical examples, a decision was made to expose the corrugation in order to provide extra storage space. As an experiential response to entrance that neglects traditional construction methods, flexibility became a design factor that was also to be incorporated.

Through joining the concept of storage and flexibility, the form took this design shape.

Wooden Curtain Door by Matharoo Associates

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2

1

Flexing Points

2

Door Movement Plan

A free flowing door movement is achieved by allowing flexibility to occur at joints where material thickness is kept to a minimum, paired with a conventional hinge to counteract the tensile stresses involved. Within this system, the indents from the corrugations become the locations for flexibility to occur, allowing for the best response in conjunction with human interaction

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4

1 - Flexible Corrugation 2 - Integrated Storage 3 - Support with Integrated hinge 4 - Supporting Beam With Incorporated Ladder System

Magnetic Locks to be embedded into the wall and door fabric, to reduce the need for moving mechanisms in printed material

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3

1

24mm

23.5mm

Hinge Design 1:1

1

2

4

15mm

3 1 2 3 4 Spatial Tolerences 1mm

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Hinge Support Ball Bearings Solid Exterior Skin Weep Holes For Excess Material To Run Out

In reaction to the length and its potential weight with incorporated storage, the hinge has been designed for security in addition to its movement. Due to the organic nature of the interior form, the hinge is completely enclosed with the door, therefore neglecting any post construction fixings, thus lending itself to the involved advantages of additive manufacture. The connection to the form is takes place at the floor slab and ceiling through a vertical pole. At 5 intervals, a tray is incorporated into the structure to carry 9 ball bearings, from which the door rests in and thus rotates smoothly when under lateral force. Outlets within these structures allow the residual material from the 3D printing process to flow away

32cm 3

3

38cm

1 - Door With Integrated Storage 2 - Floor Structure With inset Step and Storage 3 - Rubber Seal To Be Inserted Post Construction

38cm

3

19cm

90cm 39cm 52cm

Thermal Detailing

1

2

3

1:1 A thermal barrier between the interior and exterior is partially achieved through the minute tolerances that are possible through computational design and additive manufacture. A 2mm gap is situated between the door and wall structure. A 30mm recessed lip is used to extend this air gap and additionally produce a moisture barrier. For design longevity, a profile insert is integrated within the edge, allowing a standard rubber seal to be added post construction

1

3

2 3 1

Flexibility + Security Overlapping Doors

Closed

The movement within the door is intended to be achieved by decreasing the material thickness at the desired fold. A double corrugated skin allows a controlled movement whilst retaining a structural integrity when open. Furthermore, the thermal barrier at this section is retained as their are no breakages within the skin. A thin lip partially conceals and protects the corrugation, and is allowed to flex when the door opens.

2 3

1

Flexibility 1:2

2

1 - Corrugated Flexible Skin 2 - Lip Concealing and Protecting Corrugated Skin 3 - Door Structure

Security 1:2

1 - Main Door 2 - Secondary Door 3 - Integrated Magnetic Lock

In order to refrain from design and printing intricate mechanisms, the door is closed using a standardised magnetic lock system that intergrated within the door and strucutral column, and added to the structure post construction. The secondary door is secured by an overlapping lip from the main door.

1

Oculus Window Studies

The large central oculus window on the front of the building allows the user to control both light and ventilation in the living and sleeping space. The following studies examine possible schemes to manually operate these elements within the context of 3D printing.

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3 1. Flower Petal Scheme 2. Camera Aperture Scheme 3. Ribbon Light Scoop Scheme

Window Elevations And Operations

Flower Petal Window Option 1

INSIDE

OUTSIDE

OUTSIDE

SHADES IN CLOSED POSITION

WINDOW GLASS ADHERED TO INTERNAL FRAME

FLEXIBLE HALLOW SHADE W/ INTERNAL HINGES

INTERIOR FRAME PUSHES IN TO OPERATE SHADES

STATIONARY ROTATION LIMITER SHADE HINGE WALL

VERTICAL SECTION WINDOW ASSEMBLY

Window Assembly Sections

INSIDE

PUSH FRAME OUT TO OPEN WINDOW SHADES

HORIZONTAL SECTION WINDOW OPERATION

In this scheme, the radial shades flex open when the user pushes the frame outward; these curved shades then scoop the light generously into the living space. The lightweight shades allow for simple operation and clear views.

Window Elevations And Operations

Camera Aperture Window Option 2

INSIDE

OUTSIDE

INSIDE

OUTSIDE

INSIDE

OUTSIDE

1. INTERIOR FRAME 3D PRINTED IN PLACE

INTERIOR FRAME ROTATIONAL OPERATION SHADE HANDLES

SHADES IN CLOSED POSITION

2. ADHERE WINDOW PANE

SILICON ADHESIVE AND WINDOW PANE SHADES IN OPEN POSITION

3. SNAP IN OUTER SHADING FRAME

INTERLOCKING EXTERIOR FRAME WALL

VERTICAL SECTION WINDOW ASSEMBLY

Window Assembly Sections

HINGE

HORIZONTAL SECTION WINDOW ASSEMBLY

HORIZONTAL SECTION EXPLODED WINDOW ASSEMBLY

Inspired by the aperture adjustment on a camera, this scheme allows the user to dilate the shaded opening according to how much light is desired.

OUTSIDE ELEVATION

INSIDE ELEVATION

OPEN SHADES

OPEN WINDOW

Ribbon Light Scoop Window Refined Design

INSIDE

OUTSIDE

INSIDE

OUTSIDE

INSIDE

OUTSIDE

SHADE HANDLES GLASS PANE

TAUGHT SHADES

SHADE FLEXOR PIN SILICON ADHESIVE

EXTENDED LIGHT SCOOPS (FLEXED SHADES) SHADE PIVOTS FRAME

TAUGHT SHADES SHADE HANDLES SHADE FLEXOR PIN SILICON ADHESIVE

EXTENDED LIGHT SCOOPS (FLEXED SHADES) SHADE PIVOTS

2. ADHERE WINDOW PANE

FRAME

SILL

SILL

WALL

WALL

VERTICAL SECTION WINDOW ASSEMBLY

1. FRAME, SHADES, AND SILL PRINTED IN PLACE

HORIZONTAL SECTION WINDOW ASSEMBLY

HORIZONTAL SECTION EXPLODED ASSEMBLY

This window design utilizes the flexibility of the printed material to create light scoops that redirect the natural light from above to evenly and softly illuminate the interior. A central hinge allows for window operation for natural ventialtion. The llamae light scoops also provide visual privacy from the public level below. After printing, a glass window pane can easily be inserted and adhered to the inside of the window assembly. Overall, the characteristics of light redirection, window operation, visual privacy, and simple postprocessing make this window a functional and beautiful element of the overall design.

natural light

natural ventilation

visual privacy

Ribbon Light Scoop Window Refined Design

The design of the window takes inspiration from the corrugations on the exterior facade of the mirco-apartment while not formally over-shadowing the overall design on the side elevations.

It’s simple operation allows for complete control of natural light, natural ventialtion, and visual privacy to the interior.

H I N G E

Door Sections to be interlocked, with integrated hinge structure

Bathroom Door

As a result of the compact planning involved in the unit, the approach for the bathroom door relied on concealing the fixtures when not in use, and expanding into the main area when in use. This is achieved with a 3 panel hinged door that opens out traditionally and folds in half with a connected extention. The panels are designed to control the movement, allowing the starting and finishing positions to snap into place.

PHASE 3

PHASE 2

PHASE 1

21mm 1mm Tolerance

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3

2

1

16mm

32mm

1mm Tolerance

Hinge Design 1 2 3 4

1:1

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3mm Door Structure Void Internal Angled Structure Connected Central Column 5 - Seperate Panel

In order to utilise the advantages in printing technology, the techincal aspects of the hinge are completely intergrated and hidden from view. The lightweight nature of the doors allow the hinge to function solely using friction and gravity, with solid connections at the end of each panel. Angled internal ribs provide support against bending whilst allowing excess material from additive printing methods to run away.

10mm

1

2

5 3

4

40mm

15mm

1

1 2

2

3

3

4

4

5

5 6

6

7

Open

Closed

1 - Flush button 2 - Hidden cistern *capacity 10L 3 - Water emittance into basin 4 - Basin *5L 5 - Sewage/drainage pipe 6 - Pin hinge 7 - Exit to soil stack

1 2 3 4 5 6

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Flush activates closure and tilt of the basin Flexible pipe installed after printing Basin is tilted and releases water intosewage pipe Collapsable U-pipe installed after printing Stopper Air admittance valve pulls water out of basin and contains fumes

Toilet 1:10 The Folding Toilet is incorporated into the bathroom wall. When open it is used traditionally as a urinal. When shut, the lip in the wall within which it is encased can be used as a sitting bench in the shower. The entire unit can be 3D printed with the exception of the flexible piping necessary for the folding mechanism.

40cm

6cm

36cm

1 43cm

45cm

2

3 4

Technical Design 1:1 5

A simple pin hinge is used to create the foldable toilet mechanism. It is completey concealed by the ‘seat’ above and the stopper in the floor.

6

7 10cm

1 2 3 4 5 6 7

- Shower water pipe in dividing wall - Access to pipes a cistern through removable vertical plate - Sink water supply divided off from main shower pipes - Cistern water supply from grey water tank filtration system - Sink and Shower drainage to grey water tank - Toilet drainage to soil stack - Grey water tank *filtration not shown but included

3cm

1cm

Kitchen 1

2

3

4

5

1 - Sink with hidden bathtub 2 - Flexible counter space with Electrical Points 3 - Concealed Refridgerator 4 - Shelving

In a compact living environment the spacial organisation of a critical space such as the kitchen is very important. The design solution aims to provide the essentials for cooking, cleaning and storage of kitchen items whilst feeling luxury and incorporating solutions and additions that are unexpected in a space of this scale.

In a space of this scale it is important to have incorporated luxurys that reduce the feeling of a compact space.

Small scale living usually means a bathroom with only a shower, there for incorporated within the kitchen space is a soaking tub. Giving the opportunity to soak in the bathtub and watch movies on the screen

Kitchen Table

A fold-away table that can be conveniently pulled out from underneath the kitchen counter top for meal times, before being folded back flush. The hinges and support will be printed together with the table, reducing the need for separate components to be made independently and fitted together.

The dimensions of 600mm by 560mm will allow two people to sit at the table and eat together.

22 mm 22 mm

Ladder 22 mm 35 mm 280 mm

In order to maximize free space in the floor plan, the ladder was designed in such way it could be folded away when not in use. Therefore, the ladder can be completely concealed within the column.

Taking into consideration the correct position of the sleeping body, the form of the bed surface contains subtle indents where the shoulder and hips must sink further into the bed.

Bed

Shelving

Reading Light

The sleeping area is located above the bathroom, and receives direct light and ventilation from the window, as well as a view to the exterior. Some of the features existing in the sleeping are built in storage compartments, wall shelving, as well as a reading light.

In addition the bed structure also contains a built in compartment for the projector. In order to reach the bed the habitant must climb up a ladder that exists within the column.

Arrayed Spring System

1.5 mm thickness

1 mm thickness

1.5 mm depth

Bed

Spring Dimensions

23 mm

A spring system, which will also come to be with the 3D printing process. was designed o further (*&^)(&*()*&( the level of confort of the bed surface.

To accommodate for different pressure of the different parts of the body, the spring system consists of thichnesses, a 1mm and a 1.5mm.

This allows for more easily flexible areas on the bed, for instance the pillow.

The spring works due to two details. One, a hinge allows for easy rotation at pivoting point as opposed to a rigid connection. This also prevents the spring from easily breaking. Two, the thickness and flexible properties of the material allows the spring to bend at its hight peak.

Spring Mechanism

Detached Membrane

Bed Single Layer Spring System

In a single layer spring system a thin membrane is placed above the arrayed springs.

This membrane must be disconnected from actual springs in order to allow for independent movement.

In a double layer spring system the single layer is simply mirrored. The detached membrane is no longer necessary, the disconnection is now existent between top and bottom spring rows, allowing them to also move independently.

Double Layer Spring System

50mm

30mm

70mm

400mm 98mm

40mm

94mm

Floor Storage 359mm

458mm

The floor storage in the floor benefit from the depth of the slab. Access to the storage is by lifitng part of the floor which act as a lid of the storage when lifted. This is an convenient process as all of the storage opens, therefore the user can place and retrieve items efficiently.

726mm

There are two storage compartments big enough to place a foldable stool as well as other items.

A three rounded column sit in between the floor plates of the floor slab. The columns are in a 100 centre spaced grid form, this help to dissipate weight from the imposed load as well as help piping and other mechanical to be passed through the spaces.

A Grid inside the I beam represent a simple structure of a bone. Therefore making the I beam lighter and less material used for construction, whislt still retaining its strength.

Floor Structure

Section showing the structure inside the slab.

Structure mimic the fibrous form of a bone, as the material inside the bone is less but is still strong.

An Isometric showing how the the grid structure is inside the I beams.

Natural Ventilation

Heating and Cooling LED lighting and Electricity

Grey Water Recycling

Systems Overview

3D printing offers the dream of completely integrated systems. Unlike traditional building construction which assimilates systems through layers a 3D printed wall can combine structure, insulation, plumbing, heating and light in new and innovation ways.

A small space also requires smart use of space and optimized systems. Our research on 3D printing led us to how we could print pipes and other systems into our building. We have integrated a 3D printed water collection tank and capillaries in the walls for heating and cooling.

Other parts that cannot (yet) be printed such as heaters and filtration units can be integrated with the printed parts to create functional smart systems.

Plumbing and Greywater Recycling Filtration System Pump and Pressure Sensor Toilet Greywater Collection Greywater Tankh Tankless Water Heater Tap Fixture Shower Fixture

Description: The shape is optimized for rainwater run off. As our wall and roof are a continuous curvature the drains and rain collection gutters can occur right at ground level. When they have collected the rain it is taken to a large greywater tank located under the bathroom where is is filtered and used for the toilet system.

Should there be too water the tank has an overflow valve to let excess out in a controlled way.

Should there be too little a valve connected to the mainline water supply is activated.

Ideally this system could be used to provide water for the shower and sink system. But currently at this scale the filtration system required would be too large.

Hot water is provided by a tankless water heater located in the dividing wall between the kitchen and the bathroom.

2

7

3

6 4

Plumbing and Greywater Collection 1

Rain Water Collection designed and printed

2

Tankless Water HeaterRheem Rhe 13

3

Shower Fixture tbd

1

4

Tap Fixture tbd

5

5

Greywater Tank designed and printed

6

Filtration System based on Aqus by Sloan

7

Toilet designed and printed

Heating and Cooling

Description: Part of our initial goal with the notion of a 3D printed house was to have fully integrated systems into walls and floors. As our wall and ceiling are connected

Beer Refrigerator Tankless Water Heater Heat Transfer Unit Pump

The system we have currently proposed is similar to many conventional capillary floor and wall systems. The calculations for this system were based approximately on the information from Beka Klima systems who provide both heating and cooling through their capillary system. The number and spacing of capillaries was based on their mat. Our system is currently geared for heat production while we rely predominantly on natural ventilation for cooling due to the small size of the unit and a presumed location in western Europe.

1

2

Heating and Cooling

1 3

Tankless Water Heater Steibel 2.5 Mini

5

2

Small Refrigerant Unit based on a beer refrigerator

3

Heat Transfer Unit etc product tbd

4 4

Pump product tbd

5

Capillaries filled with glycol printed

Rotating Window Frame

Natural Ventilation

Hot air rises and is allowed to escape out the operable window above the bed. Cool Air is sucked in through a vent in the wall.

On a temperate day the double doors can be opened to allow air in and allow a view onto the landscape.

Vent through skin

Ceiling Light

Bed Light

Down Light

Artifical Lighting Integrated Light Due to the limited space inside the micro-apartment, it is important that the interior is well lit in order to give the impression of a much larger space to the user. To achieve this, lights have been integrated within the skin of the interior, running from floor to ceiling.

There is also a bed light for night time reading, a ceiling light fixed above the kitchen space and then a down light within the bathroom. All of these together will provide the user with plenty of illumination.

Electricity Diagram Rain Water Collection

Tankless Water Heater Shower Fixture

Tap Fixture

Greywater Tank Filtration System Pump and Pressure Sensor

This is a schematic diagram demonstrating the layout of the electrics, Transformers are required for the integrated LED lights.

The apartment also features a central switch for the lighting system, which can be programmed to be controlled through an application on a smart phone.

Ceiling Light

Exterior Wall

Bedroom Light

Interior Wall

Shade - 2mm Thick

Shade - 2mm Thick Cooling System

LED

PrevaLED

Wall Luminaires

Product : PL-CORE AC-2000-827-G1 Color: white Power [W]: 26.2 System efficiency[lm/W] : 76 Radiance Angle [째]: 110 Wavelength [nm] Color Temp [K]: 2700K Lum Flux [lm]: 2000

Product : QOD S WT Color: white Power [W]: 3.5 Radiance Angle [째]: 45 Wavelength [nm] Color Temp [K]: 3500K Lum Flux [lm]: 150

Integrated Light

LED

Exterior Wall

Bathroom Light

Electricity Diagram LED

Interior Wall

These diagrams show the specifications of the lighting within the apartment design. They are all LED light fixtures in order to achieve low energy use for the lighting system.

Shade - 2mm Thick

Flexible Light

Waterproof Membrane

Linear Light

PrevaLED

Product:DX01-W4F-854 DX01-W4F-830 Color: white Number of LEDs: 120 Power [W]: 68.0 Radiance Angle [째]: 120 Wavelength [nm] Color Temp [K]: 6500K Lum Flux [lm]: 5544

Product:LEP-CUB-AC-830-G1 Color: Warm white Power [W]: 12.5 Radiance Angle [째]: 110 Wavelength [nm] Color Temp [K]: 5400 K Lum Flux [lm]: 3000

Ceiling Light

Artificial Lighting

One of the original concepts of the design was that during the day it would allow natural light to pass through the skin and at night the process would reverse and give out a ghostly glow. With the lights integrated within the skin of the design it allows this to happen, creating a beautiful, yet eerie aura,

0 BEAMS - ONLY BEAM SPACES

1 BEAM

2000

2 BEAMS 2000

3 BEAMS 2000

1 BEAM AND HALF SHELL 2000

FULL SHELL & LIFT CHANNELS

2000

2000

BEAM 1 IN SHELL

4000 3203

2885 4000

4000 1560

1060

4000

BEAM 1 THROUGH CENTER OF GRAIVTY

4000

4000

BEAM 1

BEAM 1

SPACE FOR BEAM 1

BEAM 1 IN SHELL

40

BEAM 2

200 32

BEAM 3

200 32

BEAM 2

200 32

SPACE FOR BEAM 2

40

40

500

BEAM 2

FORKLIFT CHANNELS BEAM 2 IN SHELL

1000

1000 300

2000

BEAM 1 IN SHELL

SPACE FOR BEAM 1 IN WALL

BEAM 1

BEAM 1 IN BED

Crane Handling Studies

200 32

200 32

200 32

200 32

2000

1000

2000

1000

2000

1000

2000

1000

2000

BEAM 1 IN SHELL

BEAM 1 IN BED

THRUGH CENTER OF GRAIVTY

BEAM 2 IN COUNTER

SPACE FOR BEAM 2 IN BASE

BEAM 2 IN BASE

BEAM 3 IN BASE

BEAM 2 IN BASE

FORKLIFT CHANNELS BEAM 2 IN SHELL

In these studies, we discussed incorporating supported voids into the print to allow steel rods to be inserted for crane lifting. We explored incorporating 1, 2, and 3 beams in holes, printed masses, or exterior shells alongside the printed model. In the end, we decided the utilizing a single beam through the center of gravity provided the best solution.

STEP 0 - EXCAVATE AND EPOXY

STEP 1 - LIFT OFF PRINTBED

STEP 2 - ROTATE UPRIGHT ON CENTER BEAM

STEP 3 - PLACE (ON CART OR PALATE?)

STEP 4 - REMOVE BEAM STRUCTURE

STEP 0 - EXCAVATE AND EPOXY

STEP 1 - LIFT OFF PRINTBED

STEP 2 - ROTATE UPRIGHT ON MULTIPLE BEAMS

STEP 3 - PLACE (ON CART OR PALATE?)

STEP 4 - REMOVE BEAMS STRUCTURE

Crane Handling Studies

In addition to studying the printed support structure, we analyzed the exact process of removing the model from the printbed. Each support structure required a different amount of post-processing. For our print at Voxeljet, we are using the first handling process diagramed.

STEP 0 - EXCAVATE AND EPOXY

STEP 1 - LIFT OFF PRINTBED

STEP 2 - SECURE IN SHELL

STEP 3 - ROTATE UPRIGHT ON SHELL AND BEAM

STEP 3 - PLACE (ON CART OR PALATE?) WITH NO POST-PROCESSING

STEP 0 - EXCAVATE AND EPOXY

STEP 1 - LIFT OFF PRINTBED

STEP 3 - ROTATE UPRIGHT IN SHELL

STEP 3 - REMOVE FROM SHELL WITH LIFT CHANNELS

STEP 3 - PLACE WITH NO POST-PROCESSING

Crane Handling Studies

For our 1:1 sand print, we discussed with Voxeljet a variety of methods to lift the print out of the printbed and set it upright for display. Due to its large size, heavy weight, and brittle nature, these studies were necesary to complete the final print.

1:10 3D Printed Model

1:1 Printed Apartment

Final Review

Final Review