TransFoam_Bartlett_BPro_RC5+6_by Terry Tianyu Guo

TransFoam

Research Cluster 5&6

MArch Architectural Design, 2016-2017 The Bartlett School of Architecture|UCL

TransFoam

Lost Foam Casting Metal Structure

Tutors: Daniel Widrig Guan Lee Stefan Bassing Soomeen Hahm Igor Pantic Adam Holloway

Team Members: Tianyu Guo Luhan Yu Yixuan Wang

CONTENTS PART 01_INTRODUCTION Project Description References

_009 _011

PART 02_MATERIAL RESEARCH Pattern Material Test

_015

/Foam Sheet Clipping /Foam Block Cutting /Foam Tube Bend

PART 03_ALUMINUM CASTING CRAFT Plaster Model Casting Lost Foam Casting

_043 _053

PART 04_DESING STUDIES Logic Geometry

_077

/Interlocking /Intersect Structure /Network

Computational Structure

_087

/Shortest Walk /Detective Structure /Irregular Structure

PART 05_DESING LANGUAGE Unidirection Surface Branching

_109 _125

Multiple Directions

_157

_141

PART 05_DESING DEVELOPMENT Initial Chair Studies Node Chair Prototype Chair

_175 _183 _197

PART 06_FINAL TABLE FABRICATION Node Table Prototype Table

_213 _229

PART 07_ARCHITECTURE SPACE PROTOTYPE Overview Column Truss Slab Facade Final Proposal

_247 _249 _257 _263 _273 _281

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01_INTRODUCTION Project Description References

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01_INTRODUCTION [Project Description]

TransFoam

Tianyu Guo, Luhan Yu, Yixuan Wang

There has been a quick progression in the field of computer aided design tools in recent times, which have allowed designers and architects to be able to create simulate complex geometries and building structures. Ongoing advancement in digital fabrication methods and increasing accessibility across all industries have created new possibilities for architecture in the 21st century. Faster digital simulation has allowed for the calculation of physical phenomena, and accurate forecasting of potential results is more reliable and rapid than it has been before. With specific systems like 3D printers and robotics, the fabrication of increasingly complex structures is much easier, but there are now new problems that need solving.

Currently, most shapes can be quickly manufactured by digital fabrication technique, but there are still certain issues related to the cost of construction, restricted material selection and large scale limitation. Furthermore, completely automated fabrication systems usually require designed to pursue linear production methods, with limited flexibility or opportunities to use their initiative. As machining has high cost and time requirements, the process of creating objects is usually held back to the last stage of the design period, often producing predictable, presimulated outcomes.

On the other hand, in the context of wide-scale construction, the monotonous architecture design styles have become an inescapable phenomenon, which is the shame of architects and designers. Architecture is a part of physical environment, and architecture is also composed by complex structure and several joints simultaneously. Therefore, as architects, we should attach importance to the design methodology from the view of materiality, and rethink the relationship between joints, complex structures and architecture integrated, so as to expand the diversity of physical environment.

Under these circumstances, TransFoam group examines compounded design and fabrication methods, where tactile interaction with materials and for initiates being the basis for all research activities. When messiness and failure are taken into account as common aspects of this process, there is a clear benefit for the using both hand craft and digital tools, where computer-controlled design and manufacturing activities can be used to produce superior results. Through conducting research into these methodology and semi-automated processes, TransFoam group instigates a development of fresh, crafted aesthetic, which can portray the changes made from architecture mostly focused on representation and tools related to an architecture which provides new ideas of craftsmanship, intuition and a post-digital design sensibility.

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01_INTRODUCTION [References]

Tube fig.1: Multithrea, Kram Weisshaar fig.2: Railing chairs, Aranda Lasch

fig.1

fig.2

Transition fig.3: Human Motions, Peter Jansen fig.4: Corian Super, Amanda Levete

fig.3

fig.4

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Metal Casting fig.5: Bone Chair, Joris Laarman fig.6: Pewter Stool, Max Lamb

fig.5

fig.6

Node fig.7: vMESH, Felix Raspall fig.8: 3D Printing Structural Steel, Arup

fig.3

fig.4

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02_MATERIAL RESEARCH Pattern Material Test

/Foam Sheet Clipping /Foam Block Cutting /Foam Tube Bend

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PATTERN MATERIAL TEST Foam Sheet Cliping

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02_MATERIAL RESEARCH [Pattern Material Test] Foam Sheet Test

Foam is recommended to be burned directly with aluminium during lost foam casting, and so the burn test was conducted. Firstly, the foam sheet was evaluated, and it was very soft and easy to burn. Following the series tests (e.g. Grasp, rotation, push and pull), it was seen that foam sheet can create geometric shapes the easiest, but it was also seen that it was too soft to deform through sand pressures during lost foam casting.

[Sample A] H = 2mm

[Sample B] H = 18mm

Plasticity

Plasticity

Flammability

Flammability

[Sample C] H = 5mm Plasticity Flammability

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[Sample A1]

[Sample A3]

[Sample B]

Rotate

Pull

Grasp

Burn

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02_MATERIAL RESEARCH [Pattern Material Test] Foam Sheet Cliping

Fome Clipping Map

Foam Sheet Fabrication - Fold

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Fome Clipping Map

Foam Sheet Fabrication - Wave

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PATTERN MATERIAL TEST Foam Block Cutting

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02_MATERIAL RESEARCH [Pattern Material Test] Foam Block Test

Secondly, three types of foam block were tested. Polystyrene and Blue polystyrene were the easiest to be burned, and allowed for casting into the smoothest surfaces. However, because the foam block only can be cut or sculptured, the most obvious drawback of foam block was the limitation of plasticity.

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[Type A] Polystyrene

[Type B] Blue Polystyrene

[Type C] PU Foam

Flammability

Flammability

Flammability

Porosity

Porosity

Porosity

[Sample A] Polystyrene

[Sample B] Blue Polystyrene

[Sample C] PU Foam

Pattern

Metal Cast

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02_MATERIAL RESEARCH [Pattern Material Test] Foam Block Robotic Cutting

As can be seen, foam blocks are very hard and difficult to shape by hand, so we tried to connect it with robot arm.

We can take advantage robot to cut foam into large scale curve surface, and casting them into metal. Cutting can be controlled by setting up different tool paths.

Robot Foam Cutting Techinique

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Components

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02_MATERIAL RESEARCH [Pattern Material Test] Foam Block Robotic Scraping

We can use polystyrene foam block as mould for aluminum casting directly. Polystyrene is a kind of foam which we can cut easily with hot-wire foam cutter. Because of the accurate and stable action of robot, it can get the perfect and smooth cutting section surface. Therefore, through designing the geometry of cutting path, we can fabric any flexible shape, and casting them into metal which is a architecture material, and it also has the potential to connect into a larger scale. The design of pattern starts from the point attractor.

Through a hot-wire scrape tool, a whole surface can be cut into different texture with the transition state from different deepness cutting.

Position of Point Attractor

Robot Foam Scraping Techinique

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Position of Point Attractor

Cutting Tool Path

Cutting Tool Path

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02_MATERIAL RESEARCH [Pattern Material Test] Foam Block Robotic Cutting & Scraping

The depth of carving technique is shallow, so carving technique can generate texture on the surface, and cutting technique can cut cube into lattice structure with deeper degree of tool path. Through the combination of cutting and carving technique, a single foam cube can be cut into different moments of geometry from texture to lattice.

[Carving - Texture]

[90% Volume]

[85% Volume]

[80% Volume]

[55% Volume]

[50% Volume]

[45% Volume]

[Cutting - Lattice]

Cutting Sequences

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[75% Volume]

[70% Volume]

[65% Volume]

[60% Volume]

[40% Volume]

[35% Volume]

[30% Volume]

[25% Volume]

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02_MATERIAL RESEARCH [Pattern Material Test] Foam Block Robotic Cutting & Scraping

Through the combination of cutting and carving techinique, a single foam tube can be cut into different moments of geometry from texture to lattice.

The transition status of this aggregation indicates the sequence of robotic foam cutting technique. At the same time, polystyrene is also easy to casting, therefore, the large scale chair design is a practical proposal.

[Lattice]

[Cave]

[Texture]

Transiton

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Sections

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PATTERN MATERIAL TEST Foam Tube Bending

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02_MATERIAL RESEARCH [Pattern Material Test] Foam Tube Test

Finally, Foam tube was tested next with the shape test, showing that foam tube is soft and can be hand-shaped, motivating the researcher to conduct bend, twist, fold and rotate tests. Foam tube can be crafted into numerous different shapes by hand following cutting, and because of its softness, it can be bent or rotated.

[Sample A] D=30mm Plasticity Flammability

[Sample B] D=30mm Plasticity Flammability

[Sample C] D=20mm Plasticity Flammability

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[Sample A]

[Sample B]

[Sample C]

Fold

Bend

Twist

Rotate

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02_MATERIAL RESEARCH [Pattern Material Test] Foam Tube Bending

More complex geometry with multiple subdivisions can be developed through extra cutting times. Besides, because the foam tube is hollow, comparing with other kinds of foam, it has more assembly potential with any other straight pipes.

Foam

Cutter

a

b

c

d

Hand Craft Sequence

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Tie

Glue

Cut

Twist

Glue

Two Subdivisions

Four Subdivisions

Six Subdivisions

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03_ALUMINUM CASTING CRAFT Plaster Model Casting Lost Foam Casting

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ALUMINUM CASTING CRAFT Plaster Model Casting

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03_CASTING CRAFT [Plaster Mould Casting] Fabrication Process

The foam tube model is prepared as the pattern for pouring. The plaster is then poured over the pattern and the unit shaken so that the plaster fills any small features. The plaster sets, usually in about 15 minutes, and the pattern is burned while the mould is baked, between 120°C and 260°C, to remove any excess water.

The dried mould is then ready and the metal poured. Finally, after the metal has solidified, the plaster is broken from the cast part. The used plaster cannot be reused. The metal cast is done.

Cut

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Plug

Rotate

Mould

a. Make foam pattern

b. Set pattern into box

c. Coat with plaster

d. Take plaster mold out

e. Fire mold in kiln

f. Foam pattern disappeared

g. Pour liquid metal

h. Wait for colding

i.Collect cast

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03_CASTING CRAFT [Plaster Mould Casting] Fabrication Process

The mould is baked and foam burned at the same time. The negative space as the pouring pattern shows every detail of foam model precisely, so that the liquid aluminum could easily go through every negative space.

a. Set box

b. Coat with plaster

c. The plaster sets

d. Mould is baked

e. Pour aluminum

f. Collect cast

Workflow of Plaster Model Casting

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Section of Plaster Cast

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03_CASTING CRAFT [Plaster Mould Casting] Foam Transformation

In terms of avoiding the air which is created by liquid aluminum influence the result of the cast, the air escape system is designed.

The air escape system connected with metal pouring system so that the air can easily get out.

Channel of Air Escape Foam Tube Geometry Channel of Metal Pouring Plaster Mould

Air Escape Principle

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Foam Tube Pattern with Air Escape Channels

Air Escape Channels Replaced by Aluminum

Cut Unnecessary Branches

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03_CASTING CRAFT [Plaster Mould Casting] Air Escape System

Different air escape system lead different cast’s results: a. Result incomplete without any air escape system b. Result has holes because the air escape channel simply drilled by hand drill c. Result is close to complete with designed air escape system The result meet a great improvement from no air escape system to designed air escape system. But the final cast’s detail is still not as good as the pattern shows. Besides, preparing the mould is time consuming and low efficiency.

In order to achieve a more efficiency process and better cast’s result, a different process should be found.

Plaster Model Casting No Air Escape System

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Plaster Model Casting Drill Air Escape System

Plaster Model Casting With designed Air Escape System

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ALUMINUM CASTING CRAFT Lost Foam Casting

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03_CASTING CRAFT [Lost Foam Casting] Sand Selection

Sand is critical in direct lost foam casting, thus a sand test was conducted at the beginning of the research. The humidity, plasticity and porosity of four sand types were analysed. Following the results kiln dry sand, with its great porosity and limited humidity, was superior for heat dissipation. Additionally, there is no need for extra air escape system during the lost foam casting, thus easing the craft process.

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[Type A]

[Type B]

[Type C]

[Type D]

Kiln Dry Sand

Play Sand

Sharp Sand

Building Sand

Price

Price

Price

Price

Humidity

Humidity

Humidity

Humidity

Plasticity

Plasticity

Plasticity

Plasticity

Humidity Test [Type A]

[Type B]

[Type C]

[Type D]

Plasticity Test [Type A]

[Type B]

[Type C]

[Type D]

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03_CASTING CRAFT [Lost Foam Casting] Sand Selection

During the further test, polystyrene was used since it is a common lost foam casting material, in order to ascertain the suitability of kiln dry sand. Every test employed a same foam pattern, created by a hot wire foam cutter. The results showed that kiln dry sand is the most suitable, allowing cast surfaces to stay in good condition. Therefore, the foam tube and the kiln dray sand were selected to the further casting test.

Bury Pattern

Polystyrene Pattern

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Pour Aluminum

[Type A]

[Type B]

Kiln Dry Sand

Play Sand

[Type C]

[Type D]

Sharp Sand

Building Sand

Casting With Different Sand Types

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03_CASTING CRAFT [Lost Foam Casting] Fabrication Process

Following identification of the appropriate pattern material and mold material, the TransFoam group begin designing an entire workflow of casting fabrication. This process can be divided into four stages: foam pattern crafting; setting; pouring and collection.

a. Set foam pattern

Workflow of Lost Foam Casting

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b. Fill sand

c. Pour metal

d. Final cast

a. Make foam pattern

b. Make boundary box

c. Set pattern into box

d. Set box into sand

e. Set pouring chunk

f. Pour liquid metal

g.Collect cast

h. Cooling

i.Polish

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03_CASTING CRAFT [Lost Foam Casting] Fabrication Process

Whit Foam Tube Pattern

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Whit Foam Tube Cast - Unsuccessful

Grey Foam Tube Pattern

Whit Foam Tube Cast - Successful

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03_CASTING CRAFT [Lost Foam Casting] Framework Prototype

Mindful of the further assembly potential including other components, the pattern should be cast not only with moments but also in an accurate position. A boundary box was designed with various holes, with the end area of the foam tube able to be plugged into the corresponding hole, in order to maintain a correct position when covered with sand.

Additionally, one boundary box comprised of six wooden surfaces and four supporting beams. In accordance with this low-technology and convenient technique, it will be straightforward for anyone to cast any geometry that they require.

a. Support Beam

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b. Bottom Surface

c. Side Surfaces

Bounding Box Components

d. Side Surfaces

e. Plug Foam Tube

f. Top Surface

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03_CASTING CRAFT [Lost Foam Casting] Framework Prototype

Framework Prototype

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Plug in Wood Stick

Foam Pattern Setting

Final Cast

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03_CASTING CRAFT [Lost Foam Casting] Connection Joint Design

In order to find a best solution to solve the connections of the casting components, the TransFoam found that by using the nature hole of the tubes, the grab screw and steel tube can work together and connected two components very well. Each opening was drilled three holes to fit 8mm grab screws. And the TransFoam also tried rubber and aluminium discs to decrease the gap of joint.

Rubber Pad

[Type B] Metal Pad

Price

Price

Aesthetics

Aesthetics

Difficulty

Difficulty

[Type A]

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Grab screw

Pad

Steel Stick

Cast

[Type A]

[Type A]

[Type B]

[Type B]

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03_CASTING CRAFT [Lost Foam Casting] Geometry Limitation

The component was prepared and assembled with specific frame box. The box located the component’s movement.

Such as this four direction component, three of the openings were located by wood sticks witch were inserted into the hole. And there was a pouring opening left out of the sand.

Position of Casting

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Section of Casting Setting

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03_CASTING CRAFT [Lost Foam Casting] Geometry Limitation

In terms of the gravity effecting the lost foam casting. The components’ shape and the position when they set inside the sand were crucial factors which decided the successful rate of each casting.

As the diagrams shows that the liquid aluminium can not go through the whole structure with the first one and the third one, but only the middle component can be casted.

Unsuccessful Angle

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Unsuccessful Angle

Successful Angle

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04_DESING STUDIES Logic Geometry

/Interlocking /Intersect Structure /Network

Computational Structure

/Shortest Walk /Detective Structure /Irregular Structure

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DESIGN STUDIES Logic Geometry

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04_DESIGN STUDIES [Logic Geometry] Interlocking

The interlocking geometry has nature branch which can insert one branch into other components' opening. The transfoam study several joint solutions and used the nature curvature to design a chair prototype. This chair was a concept that one single branch component could build a functional structure.

Interlocking Sequences

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04_DESIGN STUDIES [Logic Geometry] Interlocking

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04_DESIGN STUDIES [Logic Geometry] Intersect Structure

The use of artistic technique by Transfoam Team like overlaying, interlude and parallel placement has creatively turned the foam tube into a bold and free spatial expression of rhyme and cadence. Different form of foam tube has been interspersed, which created different transparencies to various space inside the foam tube column.

Basic Elements

Assembly Diagrams

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04_DESIGN STUDIES [Logic Geometry] Network

TransFoam team generated a transition grid based on the initial regular grid, then bend the grid from the three corners of the tessellation, and then it can get a functional dome.

More complex dome structures could be generated by using more complicated bend methods.

Orinigal Grid

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Changing Density

The First TIme Bend

The Second Time Bend

Components and Straight Elements

Deformation of Network

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DESIGN STUDIES Computational Structure

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04_DESIGN STUDIES [Computational Structure] Shortest Walk

The Shortest Walk exposes one component which given a network of curves and a list of lines, calculates the shortest route from line start point to line end points in a network. It is based on a topology calculator and the A* search algorithm. The basic morphology has been explored based on it

by Transfoam team.

Shortest Walk Generation

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One Unit 1*1*1

Two Units 2*1*1

Four Units 2*2*1

Eight Units 2*2*2

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04_DESIGN STUDIES [Computational Structure] Shortest Walk

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Prototype

Grid

Prototype

Grid

Lines Pattern

Final Geometry

Lines Pattern

Final Geometry

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04_DESIGN STUDIES [Computational Structure] Shortest Walk

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Prototype

Grid

Prototype

Grid

Lines Pattern

Final Geometry

Lines Pattern

Final Geometry

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04_DESIGN STUDIES [Computational Structure] Detective Structure

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90째

100째

130째

140째

110째

120째

150째

160째

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04_DESIGN STUDIES [Computational Structure] Irregular Structure

Irregular structure starts from morphology simulation by using karamba. Firstly, TransFoam team should zone the selected area by determine the approximate points position and connect them together, then reduce the complex structure into a simple structure with a straightforward structural diagram, after that, all the joints have been determined and added, finally we got the final result. The result could be generated by change the points region in the first part.

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Points region

Connect neighbors

Reduce structure

Structural diagram

Definition of joints

Final result

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04_DESIGN STUDIES [Computational Structure] Irregular Structure

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05_DESING LANGUAGE Overview Unidirection Surface Branching Multiple Directiongs

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05_DESIGN LANGUAGE [Overview]

Following the successful casting experiment, TransFoam group investigated the material behaviour of foam tube. In ‘On Growth and Form’, Thompson proposed that the evolution of species formation is a manner of natural dynamic growth, with the new species formed having similar biological characteristics with the original. The material behaviour of foam tube is comparable to Thompson’s theory, meaning that foam tube can produce natural deformations based on the original status, following a series of hand craft sequences.

This research originated with an assessment of a single foam tube, which was dissected through the central section in order to permit the bottom section to be rotated and inserted into the central cut. Following these craft sequences, the foam tube became slanted at a specific angle that differed from the original. Meanwhile, a more crucial factor was that with the different lengths that were cut, different ranges from the natural slant foam tubes were seen, without any additional manual deformation. Moreover, if the foam tube is cut additional times, this form of influencing relationship between the cutting length and deformation ranges still exists. Consequently, the foam tube can produce more complex geometries with various subdivisions.

Based on the existing literature into material behaviour, TransFoam group built on the advantages posed by the innovative geometry in order to produce a joint system, comprising of four categories: Unidirection; Surface; Branching and Multiple Directions.

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[Unidirection]

[Surface]

[Branching]

[Multiple Directions]

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DESIGN LANGUAGE 01 Unidiraction

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05_DESIGN LANGUAGE [Unidirection] Tube Topolgy

The design of joint system was started from a single one foam tube. TransFoam team cut it through in the middle area, and plugged the bottom part into the middle gap, so as to generate the organic geometry.

Plug

Craft Sequence

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Rotate

Pull

30°

25°

20°

15°

10°

5°

Relationship of Cut-Angle

30°

25°

15°

10°

5°

Angle Marphology

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05_DESIGN LANGUAGE [Unidirection] Cutting and Subdivisions

The feature of Unidirection is that the foam tube connects one point to another. Because of the different lengths of cutting path, the geometry of foam tube has different moments of natural slanted or curved shape, which was topology deformation with different angles.

Two Subdivisions and Single Rotation

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Two Subdivisions and Twice Rotation

Four Subdivisions and Twice Rotation

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05_DESIGN LANGUAGE [Unidirection] Cutting and Subdivisions

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Final Cast of Surface Joint

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05_DESIGN LANGUAGE [Unidirection] Language Development_Transition

TransFoam team used the components of unidirection category and plugged them together so as to build a column in large scale, which has a transition status because of the topology deformation of angels of this node type. This column grows from the straight element at the bottom, and then separates in to transition parallel branches at top.

Components

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Angle

Transition

Transition Sequence

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05_DESIGN LANGUAGE [Unidirection] Language Development_Transition

TransFoam team also took advantage of the nodes of parallel in unidirection category, and plugged them together so as to generate a wall in large scale, which has a transition texture because of the topology deformation of angels.

Angles

Transition

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Angles

Transition

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DESIGN LANGUAGE 02 Surface

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05_DESIGN LANGUAGE [Surface] Tube Topolgy

Subsequently, TransFoam group attempted to break the regular impression of tube geometry further, achieving surface language. The foam tube was dissected from the top, with both parts spread out in order to stick into a surface.

Furthermore, joints were also created which had further subdivisions, by controlling the cutting times.

Cut

Craft Sequence

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Twist

Stick

0°

5°

10°

15°

20°

25°

Relationship of Cut-Surface

3cm

5cm

7cm

9cm

11cm

Surface Marphology

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05_DESIGN LANGUAGE [Surface] Cutting and Subdivisions

Subsequently, TransFoam group attempted to break the regular impression of tube geometry further, achieving surface language. The foam tube was dissected from the top, with both parts spread out in order to stick into a surface.

Furthermore, joints were also created which had further subdivisions, by controlling the cutting times.

Two Subdivisions

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Four Subdivisions

Six Subdivisions

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05_DESIGN LANGUAGE [Surface] Component Casting

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Final Cast of Surface Joint

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05_DESIGN LANGUAGE [Surface] Language Development_Surface

Different Language Behaviors

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05_DESIGN LANGUAGE [Surface] Language Development_Sprial Stair

TransFoam team take advantage of surface joint and other material to design a spiral stair. The single step is composited by two surface joints, which are merged together. Each single step can be connected to the vertical axis, which could be produced by CNC machine. This case indicates the multiple utilization of metal joints and other kinds of material, and multiple fabrication methods.

Prototype

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Assembly

Multiple fabrication methods

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05_DESIGN LANGUAGE [Surface] Language Development_Sprial Stair

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DESIGN LANGUAGE 03 Branching

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05_DESIGN LANGUAGE [Branching] Tube Topolgy

TransFoam group initiated the building of the relationship between two or more tubes. This was begun due to the strong impracticality of building an intricate architectural structure with the joints using just a single direction. Consequently, as a means of attaining the geometry that can branch from one point to multiple points, the researchers cut multiple individual tubes in the bottom section and amalgamated them.

Components

Craft Sequence

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Cutting

Glue

10°

30°

50°

70°

90°

Relationship of Cut-Angle

90°

105°

110°

115°

120°

Angle Marphology

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05_DESIGN LANGUAGE [Branching] Branching Numbers

Two Branchings

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Three Branchings

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05_DESIGN LANGUAGE [Branching] Component Casting

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Rough Cast and Polishing Cast

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05_DESIGN LANGUAGE [Branching] Language Development_Branching

The new prototype developed from the initial rotate language. We could create parallel and branch components and assemble them into prototype structure, after that, the prototype structure could be assembled again as beam structure which could be applied to building construction.

Top

Duplication

Base

Components

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Prototype

Assembly

Front View of Beam

Top View of Beam

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05_DESIGN LANGUAGE [Branching] Language Development_Cantilever

By connecting the separate branching nodes, we have got single beams in different size. Then we could continuous connect these single beams by regularly decreasing the quantity, in order to generated more complex architecture structures. By this analogy, this structure could be applied to large scale architecture construction.

Based on the dual character of Chinese bracket arch (Dougong), the framework and decoration have a big impact on the prototype. Our rotate language has been combined into inter-cross setting structure with inverted triangle form.

On the basis of the prototype, complicated cantilever structure could be assembled from four vertical directions.

Prototype

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Assembly of Cantilever Structure

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DESIGN LANGUAGE 04 Multiple Directions

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05_DESIGN LANGUAGE [Multiple Directions] Tube Topolgy

After the foam tubes were branched from one to multiple, TransFoam group continued to design the joint that could extend out multiple directions in a three-dimensional space.

For example, the researchers prepared two foam tubes with a half cutting from the top to the middle, then glued them together. Following rotation, the aggregation possessed four directions, which could also be bent into different angles. Furthermore, through a similar crafting method, a joint with three and six directions could be manufactured.

Components

Craft Sequence

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Glue

Rotation

Relationship of Cut-Angle

120°

115°

110°

105°

90°

Angle Marphology

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05_DESIGN LANGUAGE [Multiple Directions] Dierectional Subdivisions

Three Directions

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Four Dir

rections

Six Directions

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05_DESIGN LANGUAGE [Multiple Directions] Component Casting

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05_DESIGN LANGUAGE [Multiple Directions] Component Casting

Raw Cast Before Polishing

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Final Cast After Polishing

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05_DESIGN LANGUAGE [Multiple Directions] Component Casting

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06_DESING DEVELOPMENT Initial Chair Studies Node Chair Prototype Chair

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DESIGN DEVELOPMENT Initial Chair Studies

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06_DESIGN DEVELOPMENT [Initial Chair Studies] Rotation Chair

After the language design, TranFoam team tried to apply joints system into furniture scale, so our first chair design started from single type of node, which is bend node in unidirection category.

TransFoam team used bend node with 90 degrees, and connected them together into a circle geometry. However, because of the unicity of node application, it still has drawback in the seat area, which is very hard to develop into surface.

Line Pattern

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Angle Rotation

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06_DESIGN DEVELOPMENT [Initial Chair Studies] Surface Chair

Besides, TransFoam team also tried to combine the nodes of surface with branching nodes so as to design the Surface Chair with reasonable surfaces in the right place. Therefore, branching nodes were used in the back area and seat area.

Line Pattern

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Branching and Surface

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06_DESIGN DEVELOPMENT [Initial Chair Studies] Shortest Walk Chair

Shortest Walk Chair is generated by the shortest distance plug-in in Grasshopper, and the frame is constituted by rhombus, cube and trapezoid. Because of different kinds of geometry, metabolic line pattern can be generated with different angles.

The line pattern grows from a start point, which is in the middle of the chair, and select the shortest distance in the single frame.

Grid System

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Shortest Path Generation

Assembly Line Pattern

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DESIGN DEVELOPMENT Node Chair

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06_DESIGN DEVELOPMENT [Node Chair] Geometry

The previous chairs studies are material massive, so that we try to avoid the waste of material and find out the node design has the great potential to solve this problem. After a series of exploration we designed a chair just has the single deign element and could save more than a half of its aluminium.

The original “Node Chair� comes from a simple straight outline sketch, then we replace the turning places by nodes which can connect multiple direction and load forces, on the other hand, the straight parts replaced by wood sticks in order to reduce the use of metal.

Basic Structure

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Revised Geometry

Component Distribution

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06_DESIGN DEVELOPMENT [Node Chair] Fabrication Sequences

The node chair made of six separate aluminium parts and connected by ten wood sticks. After foam tube cutting and foam pattern making, all of the foam pattern should be set into certain boxes so that we could make sure the position is accurate, ensure a seamless connection for the final product.

Foam Tube Cutting

Bounding Box Components

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Foam Pattern Making

Set Pattern into Box

Three Directions Joint

Back

Four Directions Joint

Back Corner

Frameworks Design and Chair Assembly Four Directions Joint

Front Corner

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06_DESIGN DEVELOPMENT [Node Chair] Interior Plug Structure

Four Directions Joint

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Three Directions Joint

Four Directions Joint

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The cast node shows the great potential to connect multiple direction in order to create multiple space by simple pluging action.

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06_DESIGN DEVELOPMENT [Node Chair] Assembly and Sitting Test

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Assembly Sequences

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DESIGN DEVELOPMENT Prototype Chair

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06_DESIGN DEVELOPMENT [Prototype Chair] Pattern Selection

After the design of Node Chair, TransFoam team tried to design the prototype chair which utilized all kinds of language comprehensive. The pattern of prototype chair generates from triangular prism frame, and we the cross points were connected in the frame so as to produce the line structure of the chair.

Form Finding

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Lines Pattern

Geometry

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06_DESIGN DEVELOPMENT [Prototype Chair] Design Development and Assembly

The legs of prototype chair grew from unidirection components which were pure straight elements, changing directions and generating surfaces in the seat area which was a wood piece, then grew into back area with highly density surfaces, and the multiple directions components are used in armrest and support part.

[Option 01]

[Option 02]

[Selected Option]

Pure metal casting chair with the surface components for the back and seat parts, which are not easy to be fabricated

Replace the seat and back parts into timber pieces to show the combination of two materials. But the back is not easy to do CNC becasue of the geometry.

Revise the form of back piece into casting reasonable size, and keep the seat piece as wood by CNC milling.

Design Options

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Back

Branching Joint * 1

Sueface Joint * 2

Support

Armrest

Armrest

Straight Tube * 2

Seat [Wood]

Wood Seat * 1

Legs

Four Direction Joint * 3

Four Direction Joint * 3

Assembly of Chair

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06_DESIGN DEVELOPMENT [Prototype Chair] Chair Design

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06_DESIGN DEVELOPMENT [Portotype Chair] Chair Design

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06_DESIGN DEVELOPMENT [Prototype Chair] Components Fabrication

In order to indicate different materials’ behaviour, considering the limitation of tube material to be surface, TransFoam proposed the seat part of chair can be fabricated by CNC milling, and the resat components can be done by casting process, and the whole chair can be assembled together.

Base Material

CNC Milling Process Diagram

CNC Milling Wood Chair Seat

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Cut out the Connection Joints

Flip the base and set milling region

Cut out the geometry and support

Foam Pattern of Back Component

Raw Cast Before Polishing

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07_FINAL TABLE FABRICATION Node Table Prototype Table

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FINAL TABLE FABRICATION Node Table

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07_FINAL TABLE FABRICATION [Node Table] Topology Optimization

Topology optimization is a mathematical approach seeking to optimise material layout within a given design space, according to a specific set of loads and boundary conditions, such that the subsequent layout conforms to a prescribed set of performance objectives. Topology optimization has been implemented through utilizing finite element methods for the analysis, alongside optimization techniques based on the method of moving asymptotes, genetic algorithms, optimality criteria method, level sets, and topological derivatives.

Topology optimization within architectural design is the utilization of topology optimization techniques, specific to atomized shapes’ morphology. Topology optimization provides considerable potential within architectural design, in terms of being a driver of design innovation, alongside the convergence of the architectural and engineering disciplines.

TransFoam team designed the geometry of Node Table base on the result of topology optimization, which is a guide diagram in term of reasonable mechanics.

Load

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Topology Optimization Working Principle

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Step 01

Step 02

Step 03

Step 04

Structure Optimization Process

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07_FINAL TABLE FABRICATION [Node Table] Geometry

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07_FINAL TABLE FABRICATION [Node Table] Geometry

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07_FINAL TABLE FABRICATION [Node Table] Assembly The Node Table is assembled by the components from the joint system. TransFoam team tried to use current joints with their own design language to reflect the structure diagram.

Because aluminium is strong enough, the assembly of joints can be a table support structure, carrying very heavy load, such as a piece of glass.

Components Assembly

Components with Boundary Boxes Before Casting

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FINAL TABLE FABRICATION Prototype Table

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07_FINAL TABLE FABRICATION [Prototype Table] Assembly

After the success of chair and table prototypes, the TransFoam team tried to use different multidirectional components to create horizontal structure table. The table was constructed by 13 components and 7 straight elements. The TransFoam team managed to use the most efficient structure to build a table with both functional and ornament.

[Surface Joint *4]

[Three Directions Joints *9]

[Glass *1]

Component Explosion

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[Straight Elements *7]

[Rubber Pad *4]

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07_FINAL TABLE FABRICATION [Prototype Table] Geometry

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07_FINAL TABLE FABRICATION [Prototype Table] Geometry

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07_FINAL TABLE FABRICATION [Prototype Table] Assembly

The fabrication process of the prototype table is following the same workflow. After finishing the casing and assembly process, polishing process is necessary so as to make sure the final material appearance is fine.

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08_ARCHITECTURE SPACE PROTOTYPE Overview Column Truss Slab Facade Fianl Proposal

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08_ARCHITECTURE SPACE PROTOTYPE [Overview] Space Elements

The new architectural space prototype has been generated by combining our specific joint system, which included five initial elements: column, beam, faรงade, slab and corner. We did space design through using these prototype. By applied and connected these joints with straight elements, large scale architecture space could be generated and implement.

Column

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Truss

Slab

Facade

Corner

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ARCHITECTURE SPACE PROTOTYPE Column

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08_ARCHITECTURE SPACE PROTOTYPE [Column] Geometry

The column design has utilized our previous joint elements to designed a series of column prototype. These column prototype has presented a growing trend which start from straight elements, and at the capital part the elements grow out of the branches from different directions. They could naturally get involved into architecture space system and connect all the structure parts together.

Column Prototype 02

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Column Prototype 02

Column Prototype 03

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08_ARCHITECTURE SPACE PROTOTYPE [Column] Assembly

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ARCHITECTURE SPACE PROTOTYPE Truss

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08_ARCHITECTURE SPACE PROTOTYPE [Truss] Geometry

The truss generated by using our branch languages. By applied more connection methods we have got several trusses in different density, which given more design options to us while satisfied the requirement of different structural strength.

Meanwhile, we also have transparent components which could convert between different diameter’s elements.

Connect with truss D=60mm

Connection with Different Elements

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Connect with truss D=60mm

Connect with truss D=60mm

Truss Type 01

Truss Type 02

Truss Type 03

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ARCHITECTURE SPACE PROTOTYPE Slab

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08_ARCHITECTURE SPACE PROTOTYPE [Slab] Geometry

On the basis of a load diagram, the entire geometry has been generated from a mesh grid. We have increased the density of the load bearing area to match the requirement of the load diagram by adjust the density of the mesh grid.

After that, a specific tail has been designed for the given load diagram.

Support

Support

Load Area

Support

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Support

Tails

Slab

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08_ARCHITECTURE SPACE PROTOTYPE [Slab] Different Slab Options

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Slab Option 01

Slab Option 02

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ARCHITECTURE SPACE PROTOTYPE Facade

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08_ARCHITECTURE SPACE PROTOTYPE [Facade] Geometry

Based on the achievement of Node Table design, TransFoam team developed it into facade system, which is composied by the table prototype structure. This facade system reveals the combination between glass material and metal joints structure. Besides, the transition deformation of structure can influence the glass geometry.

Simple Structure and Flat Glass

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Transition Structure and Organic Glass

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08_ARCHITECTURE SPACE PROTOTYPE [Facade] Structure Reduction

Facade Option 01 - High Density

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Facade Option 01 - Medium Density

Facade Option 01 - Low Density

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ARCHITECTURE SPACE PROTOTYPE Final Proposal

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08_ARCHITECTURE SPACE PROTOTYPE [Final Proposal] Structure Reduction

Finally, TransFoam team took advantage of all kinds of joints and current structure prototypes to design architectural scenario which has a villa function. Farnsworth House can be a initial reference, and the site will be same as Farnsworth House, which is in the Illinois, US. This villa design started from two simple massings with different scales, then two massings were divided into three parts for different functions. After the function organization, there was the deformation in the overlapping area so as to deform the main entrance and routes. This case indicates the power of low-tech lost foam casting technique, and the application potential in the architecture of joints system.

The United States

Illinois

The Farnsworth House by Mies van der Rohe, 1954

Site Location

Slab

Truss

Facade

Column

Floor

Staircase

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Structure System

Massing

Function

Deformation

Traffic

Roof Envelope

Slab Structure

Terrace

Facade Structure Bed Room

Staircase

Living Room

Kitchen

Floor Structure Terrace

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CONCLUSION

During this research, TransFoam group implemented an original design methodology, in order to rethink the relationship between materiality, joints, complex structures and architecture. In the context of volume construction, monotonous architecture design styles appear to have become a predictable phenomenon, with the loss of diversification a significant tragedy for architecture and cities. As a fundamental aspect of complicated structure and architecture, the role of joints requires reconsideration, in order to avert monotonous and non-designed joints.

Meanwhile, despite the emergence of digital techniques extending the possibility of complex geometric design and fabrication methods, architects may be induced to overlook the significance of materiality.

Resultantly, in this project, the exploration of joints initially began with a series of experiments concerning materials selection and fabrication techniques. Consequently, TransFoam group incorporated foam tube, which has high plasticity properties, with the lost foam casting technique, which is a low-tech and high-efficiency method, thus creating an innovative joint system characterised by abundant diversity in relation to geometry, subdivision and multiple directions.

Consecutively, Topology Optimisation, as an assistant parametric design technique, was incorporated into the preliminary design stage of complicated structural designs, in order to provide architects with guidelines for design that utilises a joint system.

In fact, this design methodology can be considered differently. In terms of the lost foam casting method, the diversity of joints is dependent upon the geometric creation ability of the pattern material; foam tube is not the sole option available, for example it could be replaced by various other flammable and flexible materials. Furthermore, due to restrictions on hand crafting, aluminium provides the most appropriate material for this research. However, considering the requirement of materials strength during practical construction projects, it is evident that other kinds of metal, for example iron, steel and cooper, may provide alternative casting materials during lost foam casting. Moreover, through utilising robotic arms, foam may be bent and rotated more precisely and efficiently, rather than adopting the hand craft and boundary box system.

Nevertheless, this investigation also faced certain limitations. One problem concerns error mitigation. Because the cast cannot be absolutely the same as the pattern in lost foam casting, these uncontrollable errors will result in certain problems during fabrication of parts at an architectural scale. Secondly, imperfections were seen in terms of the geometric design. This means that certain parts of the joint pattern have excessive deformation; these will become the weakest sections of this joint following casting. Consequently, the geometric design of joints should be given consideration regarding both aesthetics and mechanics, being tested rigorously prior to volume construction.

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MArch Architectural Design The Bartlett School of Architecture|UCL 2016-2017