Adaptive Digital Manufacturing of Computational Architecture.
Adaptive Digital Manufacturing of Computational Architecture. Computational design innovations in clay manufacturing and vernacular architecture: reshaping tradition for contemporary sustainability.
RAIVATI DANDIWALA I 2332808
RESEARCH ARTICLE I TERM 03
TUTOR: DR. FULVIO WIRZ
MA ARCHITECTURE AND URBANISM
UNIVERSITY OF EAST LONDON
Student document publication, meant for private circulation only. All rights reserved.
No part of this document will be reproduced or transmitted in any form or by any means, electronically or mechanically, including photocopying, xerography, photography and videography recording without the written permission from the publisher, Raivati Dandiwala and Anant National University.
University of East London, Docklands Campus, London.
E16 2RD
ORIGINALITY STATEMENT
I hereby declare that this submission is my own work and it contains no full or substantial copy of previously published material, or does not even contain substantial proportions of material which has been accepted for the award of any other degree or diploma of any other educational institution, except where due acknowledgment is made in this graduation Project.
This project is a combination of studies completed during the tenure of term one and term two in MA Architecture and Urbanism.
Moreover, I also declare that none of the concepts are borrowed or copied without due acknowledgment. I further declare that the intellectual content of this Research project is the product of my own work, except to the extent that assistance from others in the project’s design and conception or in style, presentation and linguistic expression is acknowledged. This Research project (or part of it) was not and will not be submitted as assessed work in any other academic course.
COPYRIGHT STATEMENT
I hereby grant University of East London the right to archive and to make available my Research project in whole or in part in the University Library in all forms of media, now or hereafter known, subject to the provisions of the Copyright Act.
I have either used no substantial portions of the copyrighted material in my document or I have obtained permission to use copyright material.
ACKNOLEDGEMENT
I would like to express my sincere gratitude to Dr. Fulvio Wirz, former associate at ZHA and senior professor at the Architecture, Computing, and Engineering Department at the University of East London, for his invaluable guidance and support throughout the research process. His expertise, insights, and encouragement have been crucial in shaping this research paper.
I am also thankful to dFuel Lab for their guidance and support during the research experiments on clay 3D printing. My professor, whose continuous presence, motivation, and advice were invaluable in steering this work towards its successful conclusion, deserves special recognition. I would also like to extend my appreciation to my team members, whose collaboration, insights, and encouragement have been instrumental in bringing this work to fruition.
1. INTRODUCTION
1.1 Statement of Research Intent
2. Contextualisation
2.1 Historical Evolution of Clay Manufacturing in Construction and its Influence on Gothic Architecture
2.2 Vernacular Architecture: An Examination of its Evolution: Past, Present, and Future with a Midjourney Perspective
2.3 Key Factors Shaping Architectural Practices
2.3.1 Resource Availability in Construction
2.3.2 Comparative Analysis of Skilled Workforce in Fabrication Techniques between Historical and Contemporary Contexts
2.3.3 The Impact of Digital Manufacturing on Architecture: A Historical, Climatic, and Local Cultural Perspective
2.3.4 Precedent Study and Comparitive Analysis
2.3.5 Sustainable Material Study - Clay
3. Transformative Strategy of Computational Design and Artificial Intelligence
3.1 Introduction to Computational Design and Digital Fabrication
3.2 Adapting Nature and Gothic Architectural Strategies into Contemporary Design
3.3 Incorporating Computational Techniques and Artificial Intelligence in the Croydon Town Center Project and Bench
3.4 Design Development for Housing Systems
4. Clay Production in Contemporary Architecture
4.1 Introduction to Clay Manufacturing
4.2 Material Efficiency in Contemporary Architecture
4.3 Achieving Production Accuracy with Modern Clay Manufacturing Techniques
4.4 Geometric Customization as a Design Tool in Contemporary Architecture
5. Achieving a Comprehensive Solution
5.1 Testing and Prototyping at Small Scales with Implications for Large-Scale Implementation
5.2 Tool Path Design Utilizing Grasshopper and Cura
5.3 Managing and Ensuring Availability of Varied Sizes
5.4 Transportation Considerations in Contemporary Clay Construction
5.5 Modifications and Fittings in Clay-Based Architectural Solutions
5.6 Proposal for Clay 3D Printed Modular Housing Components
6. CONCLUSION
7. BIBLIOGRAPHY
In this architectural research paper, we undertake an engaging exploration of the complex interconnection between clay manufacturing, architectural design, and advanced technology. This extensive study is a deliberate endeavor to unveil the historical foundations, decode the present realities, and envisage the future trajectories of architectural practices. Our expedition commences with an exploration of the historical evolution of clay manufacturing and its profound impact on the realm of Gothic architecture. Subsequently, we journey through the rich tapestry of vernacular architecture across diverse temporal and geographical landscapes. Key factors that have left indelible imprints on architectural practices are meticulously examined, encompassing the availability of resources, the evolution of workforce skills, and the transformative influence of digital manufacturing. Our journey is further illuminated by the assimilation of contemporary technology and computational design methodologies, vividly exemplified through practical case studies such as the Croydon Town Center Project and Bench. As we delve deeper into the core of architectural evolution, we skillfully adapt age-old architectural strategies into modern design paradigms, finding inspiration in the eloquence of nature and the grandeur of Gothic architecture. The narrative is enriched by an extensive exploration of the myriad advantages of clay production in modern architectural practice, unveiling the virtues of material efficiency, precision in production, the creativity of geometric customization, and the vast panorama of design possibilities. With a keen eye on practical implementation, we navigate the intricacies of testing, tool path design, size management, and the logistics of transportation in contemporary clay-based construction. In summation, this research essay offers a contemplative synthesis of our findings, grounded in a rich tapestry of references and resources that have nourished this intellectual odyssey.
1.1 Statement of Intent
The primary aim of this architectural research paper is to investigate the intricate relationship between clay manufacturing, architectural design, and modern technology. This research seeks to unravel the historical evolution of clay manufacturing, its influence on architectural styles such as Gothic architecture, and its relevance in contemporary architectural practices. By examining key factors that have shaped architectural approaches, integrating modern technology and computational design methods, and showcasing practical case studies, this research intends to provide a comprehensive understanding of how clay can be employed as a sustainable and innovative building material in today’s architectural landscape.
Figure01_Photograph of Clay workshop area_University of East London
Exploring the historical legacy of clay in construction, particularly its influence on Gothic architecture, highlights its eco-friendly and resource-efficient nature. This historical wisdom serves as a compelling precedent for contemporary sustainable architectural practices, emphasizing the enduring relevance of clay as a green building material. When combined with modern advancements in digital manufacturing, clay becomes even more versatile, allowing for precision and expanded design possibilities. Furthermore, the adaptability of clay to local climatic conditions and cultural contexts underscores its value as an eco-conscious, context-aware building material. By bridging the historical with the innovative, architects and designers can reduce the environmental footprint and promote sustainability in construction practices.
2.1 Historical Evolution of Clay Manufacturing in Construction and its Influence on Gothic Architecture
The historical evolution of clay manufacturing in construction and its profound influence on Gothic architecture unveil the enduring wisdom of this building material. Clay manufacturing involves the extraction and processing of clay into bricks or blocks for construction. Its influence on architectural practices is multifaceted, stemming from its natural abundance and adaptability to various climates. Through the lens of history, clay has been considered a wise option due to its sustainable and resource-efficient characteristics. An excellent illustration of this can be found in India’s Kutch district, Gujarat, where traditional clay “bhunga” houses are still in use. These homes exemplify the resourcefulness of clay as a building material, as they provide exceptional insulation and are well-suited to the arid climate of the region. In the context of Gothic architecture, clay was notably employed in the creation of ornate terracotta decorations adorning cathedrals and churches. The enduring appeal of clay as a building material, both historically and in contemporary practices, underscores its time-tested sustainability and versatility in architectural construction.
2.2 Vernacular Architecture: An Examination of its Evolution: Past, Present,
and Future
A captivating exploration of the history of vernacular architecture unveils a diverse range of design and construction techniques intricately woven into the cultural and environmental contexts of their respective epochs. In the past, the ethos of vernacular architecture was firmly grounded in the limitations of available resources and traditional building practices. For instance, in regions with ample clay deposits, adobe bricks were meticulously shaped by hand and sun-dried, while thatch roofing was employed in areas with abundant reeds or straw. This resource-driven approach gave rise to a plethora of unique architectural identities, from the adobe structures of the American Southwest to the thatched cottages dotting the British countryside.
Fast forward to the present, and we find ourselves at the precipice of a transformative era, propelled by a trove of advanced resources and technologies. Clay, a material with a rich history in vernacular architecture, is experiencing a renaissance in construction. The advent of clay 3D printers allows architects and designers to sculpt intricate, customized structures with precision, such as intricate clay furniture pieces or modular clay-based housing systems. Robotic construction processes, guided by artificial intelligence, facilitate the efficient assembly of clay blocks, opening doors to cost-effective, large-scale housing projects in regions with rich clay resources.
The future evolution of vernacular architecture and clay manufacturing holds the promise of continued innovation. We can anticipate a reimagining of traditional design principles within the context of contemporary technology. Sustainable, clay-based architectural solutions, informed by the wisdom of the past, will likely become integral in eco-conscious urban development, adaptive to climate variations and culturally resonant. This future envisions a harmonious synthesis of the timeless principles of vernacular design and the limitless potential of modern technology, creating architectural wonders that not only respect their heritage but also embrace the possibilities of the present and beyond.
2. 3 Key Factors Shaping Architectural Practices
Within the architectural domain, several critical factors are instrumental in influencing the trajectory of architectural practices. These factors navigate the delicate balance between tradition and innovation, history and modernity.
2.3.1 Resource Availability in Construction
Resource availability is the cornerstone of architectural endeavors, and the choice of building materials significantly hinges on what is locally accessible or can be efficiently imported. Clay, a timeless building material, is often obtained from nearby sources due to its widespread abundance. In the context of vernacular architecture, communities have long relied on locally sourced clay, resulting in structures that seamlessly blend with their surroundings. For instance, the adobe homes of the American Southwest are emblematic of this resource-efficient approach, as they utilized the region’s plentiful clay to craft sun-dried bricks. In contemporary architectural practices, the scope is broader, with a multitude of materials available. However, this richness of choice is ushering in an eco-conscious paradigm shift. Clay, with its sustainable properties and local sourcing, is regaining prominence. Its minimal environmental impact and versatility make it a preferred resource in sustainable architecture. An illustrative example is Casa Caldera in Arizona, where architects are revisiting clay as a building material, emphasizing its resource-efficiency and environmentally friendly attributes, setting the stage for sustainable architecture that aligns with the vernacular spirit while embracing modern resources.
2.3.2
Comparative Analysis of Skilled Workforce in Fabrication Techniques between Historical and Contemporary Contexts
A comparative analysis of skilled workforce capabilities reveals the dynamic evolution of architectural craftsmanship. In historical contexts, the execution of clay-based construction often necessitated a substantial labor force due to the intricate, time-consuming techniques involved. Communities relied on skilled artisans who honed their craft over generations, imbuing clay structures with a unique charm and character. In contrast, contemporary architectural practices are witnessing a transformation in workforce dynamics. The advent of digital tools, such as clay 3D printers and automation, has streamlined construction processes. These modern technologies empower architects and builders to create intricate, clay-based designs with precision, reducing the reliance on a vast labor force. An illustrative instance is the Digital Grotesque project, where traditional craftsmanship intersects with cutting-edge technology to craft complex clay-based architectural forms, exemplifying the seamless blend of historical skills with contemporary design techniques. This paradigm shift not only enhances the efficiency of construction but also paves the way for sustainable architecture through resource-efficient methods.
2.3.3 The Impact of Digital Manufacturing on Architecture: A Historical, Climatic, and Local Cultural Perspective
The impact of digital manufacturing is monumental in reshaping architectural practices. Historically, it empowers architects to reinterpret traditional design principles through the lens of modern technology, with examples like the Sagrada Familia in Barcelona. This centuries-old architectural masterpiece is being realized with 21st-century technology, enabling the creation of intricate, organic clay and stone forms. Digital manufacturing is a game-changer for responding to climatic conditions, as exemplified by the Al-Bahr Towers in Abu Dhabi. These structures employ advanced digital techniques to create adaptive, sun-shading elements inspired by traditional Islamic lattice patterns, showcasing the marriage of heritage inspired design with modern technology. Moreover, digital manufacturing celebrates local cultural perspectives. The Cultural Centre La Gota in Spain, with its clay-clad, digitally designed façade, beautifully fuses contemporary construction techniques with regional identity, epitomizing the fusion of modernity and local culture. Economically, digital manufacturing offers benefits in reducing material waste and streamlining the construction process, contributing to sustainable architecture. The convergence of technology, tradition, and cultural sensitivity in digital manufacturing reflects a path toward a more resource-efficient, eco-conscious, and harmonious architectural future.
In summary, these key factors are pivotal in shaping architectural practices, representing a complex interplay between resource availability, workforce capabilities, and the impact of digital manufacturing. Architects are tasked with navigating the realms of vernacular and modern design, drawing inspiration from history, local culture, and digital tools to create a sustainable, culturally rich architectural future that celebrates heritage while embracing the possibilities of the present and beyond.
2.3.4.1 Tecla house 3D-printed from locally sourced clay
Bologna-based architectural firm Mario Cucinella Architects and experts in 3D printing, WASP, have united their efforts to introduce an extraordinary low-carbon housing prototype, aptly named “Tecla.” This visionary project marks a significant milestone in the realm of 3D-printed architecture, blending advanced technology with the sustainable virtues of clay. The term “Tecla,” derived from the fusion of “technology” and “clay,” symbolizes the synergy between groundbreaking construction methods and the inherent qualities of clay. The design process was spearheaded by Mario Cucinella Architects, while Wasp assumed responsibility for the engineering and construction aspects, making use of clay sourced locally from a nearby riverbed. This introduction sets the stage for an exploration of the exceptional partnership and the outstanding features of the Tecla housing prototype.
Design Philosophy:
The Tecla House embodies a pioneering design philosophy that harnesses 3D printing technology to craft a structure that is both eco-friendly and aesthetically pleasing. This synopsis underscores how the house is crafted using a large-scale 3D printer, intricately layering locally acquired clay to construct the walls and intricate architectural elements. The design philosophy emphasizes the fusion of innovative technology and environmentally conscious principles.
Clay as the Principal Material:
The selection of clay as the primary material for Tecla House was a deliberate choice, motivated by its unique attributes and environmental advantages. This summary delves into the rationale behind choosing clay, including its local availability, natural abundance, and compatibility with 3D printing methodologies. Clay offers a sustainable substitute for traditional construction materials, contributing to reduced carbon emissions and waste production.
Figure03_ Front View of Tecla house_Arch Daily
Material Characteristics:
The choice of clay for Tecla House hinges on its exceptional material characteristics. This concise exploration delves into clay’s thermal attributes, which encompass its capacity to regulate temperature and offer insulation, ultimately fostering a comfortable living atmosphere. Additionally, clay’s intrinsic charm aligns seamlessly with the natural surroundings, unveiling the potential for organic design.
Sustainability and Local Sourcing:
The use of locally procured clay in Tecla House underscores a commitment to sustainability and regional collaboration. This summary underscores how the incorporation of local clay minimizes energy consumption in transportation and bolsters the regional economy. By prioritizing sustainable materials and practices, Tecla House exemplifies a holistic approach to environmentally friendly construction.
In essence, Tecla House serves as a paragon of innovative design and sustainable construction. Through the fusion of 3D printing technology and clay sourced from the local environment, this house epitomizes a forward-thinking design philosophy that melds state-of-the-art techniques with eco-conscious materials. Tecla House embodies a harmonious fusion of technology, sustainability, and aesthetic allure in contemporary architecture.
Figure04_ View of Tecla house from inside_Arch Daily
Figure05_ The prototype was developed as a response to climate emergency_ Photograph is by Italdron_Dezeen
Figure07_ The prototype_Digital Trends
Figure06_ The prototypes can be constructed in 200 hours_ Photograph is by Italdron_Dezeen
Figure08_ Undulating curved layers provide structural stability. Photograph is courtesy of Wasp_Dezeen
Figure09_Execution of house through 3D Printing_Additive
Figure10_Sectional Elevation_ArchDaily
Figure11_Sectional Elevation_ArchDaily
Figure12_Floor Plan_ArchDaily
2.3.4.2 - Mexico merges 3D Printing + Recycling Pavilion having 3d printed clay blocks between concrete beams
Nestled in Mexico, this pioneering architectural endeavor showcases the convergence of 3D printing technology and recycling in the creation of a distinctive pavilion structure. The project embodies a progressive approach to sustainable construction, illustrating the potential of fusing cutting-edge technology with environmentally considerate design principles. Within this pavilion, 3D printed clay blocks are strategically positioned between concrete beams, presenting a seamless integration of both traditional and contemporary building materials.
Design Philosophy:
The Mexican pavilion embodies a progressive design philosophy that amalgamates 3D printing and recycling methodologies. This brief emphasizes the central role played by 3D printed clay blocks in the construction, serving as the principal structural components thoughtfully inserted between the concrete beams. The design approach underscores the fusion of state-of-the-art technology and eco-friendly practices.
Clay as the Key Material:
Clay was deliberately selected as the primary material for the 3D printed blocks in the pavilion for a multitude of reasons. This summary delves into the advantages of utilizing clay, encompassing its abundant natural presence, recyclability, and its favorable characteristics for 3D printing. Clay provides a sustainable substitute for conventional construction materials, advocating environmental mindfulness and reducing the project’s carbon footprint.
Figure13_ 3D-printed clay blocks vault between beams as lost formwork_DesignBoom
Figure14_ the elegant geometry is sculpted by varying width and depth by computational design methods developed at MIT_DesignBoom
Material Characteristics:
Clay’s inherent characteristics render it an ideal choice for the pavilion’s design. This brief underscores clay’s capacity to endure compressive forces and its thermal properties, which bolster insulation and temperature regulation. Moreover, clay unlocks avenues for intricate detailing and personalization, elevating the pavilion’s aesthetic allure and design potential.
Sustainability and Recycling:
The selection of clay aligns seamlessly with the project’s focus on recycling and sustainability. This synopsis underscores how clay, being a natural and recyclable material, aligns with the principles of a circular economy and minimizes waste production. By leveraging 3D printing technology in conjunction with recycled clay, the pavilion presents an inventive strategy for sustainable construction practices.
To summarize, the pavilion project in Mexico epitomizes the amalgamation of 3D printing technology and recycling, employing 3D printed clay blocks in between concrete beams. The adoption of clay as the primary material provides a sustainable and adaptable solution, simultaneously championing ecological awareness and advancing the frontiers of contemporary architectural possibilities.
Figure15_ the outdoor pavilion utilizes the existing concrete structure and 3D-printed elements_image by Arturo Arrieta_DesignBoom
Figure16_ the process of 3D-printing clay blocks in the MIT lab_DesignBoom
Figure17_ 3D-printing sculpts blocks of varying width and depth with clay made by local soil_DesignBoom
Tecla House - 3D-Printed
Construction Method:
Mexico Merges 3D Printing + Recycling - Pavilion:
Construction Method:
Tecla House employs advanced 3D printing technology to fabricate its structure using locally sourced clay. The process entails the meticulous deposition of clay layer by layer, achieved through a large-scale 3D printer, which shapes the walls and architectural elements of the dwelling. This construction method adheres to the principles of additive manufacturing, with the clay being carefully extruded to craft the desired forms.
Frame Structure:
Tecla House embraces a monolithic design philosophy, where the walls themselves serve as the primary load-bearing elements, obviating the necessity for additional frame structures. The 3D printed clay forms an inherently self-supporting structure that beautifully combines aesthetics with functionality.
Clay Sourcing:
The clay employed in Tecla House is locally sourced, often originating from nearby riverbeds or other regional clay deposits. This sustainable approach significantly reduces transportation expenses and environmental impact while simultaneously contributing to the bolstering of the local economy.
The pavilion in Mexico marries 3D printing technology with recycling practices in an innovative construction approach. This architectural gem showcases the integration of 3D printed clay blocks within a framework of concrete beams. This hybrid construction method synergizes the robustness and longevity of concrete with the aesthetic allure of clay. The clay blocks are meticulously arranged to shape walls and other architectural components within the concrete beam framework.
Frame Structure:
In the case of the pavilion, a frame structure is established through the use of concrete beams. These beams assume the primary role of providing structural support while creating the foundational framework. The spaces between these beams are ingeniously filled with 3D printed clay blocks, effectively forming walls and partitions that contribute to the pavilion’s architectural integrity.
Clay Sourcing:
The selection of the specific clay source for the pavilion may vary depending on the project’s context. Nevertheless, there is a prevalent emphasis on the utilization of locally available clay resources, a practice aimed at reducing environmental impact and fostering regional integration. This conscientious approach aligns with principles of sustainability and responsible sourcing.
2.3.4.1
Usage of clay as a Building Material
Clay, as a foundational construction material, holds great significance and offers a multitude of advantages that make it an essential element in the construction industry. First and foremost, its abundance and wide availability make it easily obtainable and cost-effective. This accessibility reduces the need for extensive transportation, promoting sustainable and environmentally friendly construction practices.
Secondly, clay possesses remarkable thermal properties, providing natural insulation and temperature regulation. It plays a crucial role in maintaining indoor comfort by retaining warmth in colder seasons and ensuring cooler interiors in hot climates. This energy-efficient aspect of clay reduces the reliance on artificial heating and cooling systems, contributing to energy conservation and lessening environmental impact.
Furthermore, clay exhibits exceptional durability and longevity, providing structures constructed with it the ability to endure over time. Its ability to resist fire, pests, and decay ensures the long-term safety of buildings, reducing maintenance requirements and long-term costs. Additionally, clay is a versatile material, easily molded and shaped, offering endless possibilities for architectural design. Its pliability allows for intricate detailing, graceful curves, and unique forms that enhance the aesthetic appeal of structures.
Beyond its technical merits, clay also fosters a connection to cultural heritage and a sense of place. Its use in construction reflects the traditions and local identity of communities, preserving cultural heritage and fostering a sense of belonging. Finally, clay represents a sustainable and environmentally responsible choice for building materials. It is non-toxic, recyclable, and biodegradable, minimizing environmental pollution and waste. Its low carbon footprint, renewable nature, and minimal energy requirements during production further support sustainable construction practices.
In essence, the indispensability of clay as a building material arises from its abundance, thermal performance, durability, adaptability, cultural significance, and environmental sustainability. Its integration aligns seamlessly with the principles of sustainable development, resulting in the creation of healthier, more energy-efficient, and aesthetically pleasing built environments.
Figure18_Benefits of building with Clay_Wienerberger
2.3.4.2 Advantages of Clay Enabled by Modern Technology
The advent of modern technology has heralded a transformation in the use of clay as a building material, offering a host of benefits that make it exceptionally advantageous in construction processes.
Sustainability: Modern technology has positioned clay as a sustainable choice for construction projects. Advanced manufacturing techniques like 3D printing and computational design enable precise and efficient use of clay resources, minimizing waste and maximizing material utilization. Moreover, local sources of clay can be enhanced with natural additives or stabilizers to strengthen their properties, resulting in more robust and enduring structures. This sustainable approach significantly reduces the environmental impact associated with traditional construction methods, fostering a greener and more eco-friendly built environment.
Cost Efficiency: The integration of modern technology into clay-based construction has significantly improved cost-effectiveness. Innovations such as 3D printing, which allows for automated clay layering, expedite the construction process, ultimately reducing labor costs and project timelines. Additionally, meticulous control over material usage and the ability to refine designs through computational tools contribute to substantial cost savings. The widespread availability of clay in many regions further bolsters its cost-effectiveness as a building material.
Time Optimization: Modern technology has dramatically reduced the time required for clay-based construction projects. 3D printing techniques enable the rapid fabrication of clay components, eliminating the need for manual bricklaying or intricate detailing. The utilization of computational design tools streamlines the construction process by generating efficient geometries and minimizing design iterations. The time saved during construction not only enhances project efficiency but also expedites occupancy, addressing the pressing demand for swift housing and infrastructure development.
In summary, modern technology has brought significant enhancements to the use of clay in construction. The sustainable practices, cost efficiency, and reduced construction timelines achieved through modern techniques like 3D printing and computational design have elevated clay to the status of a highly advantageous material. These innovations not only amplify the overall efficiency of construction projects but also contribute to the promotion of sustainable, cost-effective, and time-efficient solutions for the building industry.
3. Transformative Strategy of Computational Design and Artificial Intelligence
3.1 Introduction to Computational Design and Digital Fabrication
Computational Design is a method that leverages various parameters and algorithms to address design challenges through sophisticated computer processing. The designer’s creative process is deconstructed into discrete computer-coded steps. This data, in conjunction with project-specific parameters, serves as input for software, which generates algorithms capable of producing design models or comprehensive design analyses. After the initial programming, the design evolves into a dynamic and repeatable process. Unlike traditional methods, where designers often rely on their knowledge and intuition to create designs passively, Computational Design enables a more proactive and data-driven approach. This approach opens the door to considering a broader spectrum of design possibilities while also optimizing the allocation of time and resources. Computational design, once integrated, becomes a potent and efficient tool for enhancing productivity. (See Figure for reference)
Digital Fabrication: Revolutionizing Architectural Design and Construction
Digital Fabrication has revolutionized architectural design methods and construction techniques, capturing the attention of professionals in architecture, engineering, and industrial design. These advancements have undergone rigorous evaluation based on criteria like efficiency, product quality, and real design potential, and the results have been lauded by experts. The advent of digital fabrication has not only reshaped the future of various industries but has also redefined the very concept of design.
Architects have employed Computer-Aided Design (CAD) software for over three decades to create technical drawings, marking a departure from the earlier reliance on intricate hand drawings and craftsmanship skills. Concurrently, the CAD/CAM manufacturing sector within aeronautical engineering began to introduce innovative concepts and methodologies. Architects, influenced by cutting-edge engineering and industrial design technologies, swiftly adopted new modes of operation. This transition prompted architects to explore digital fabrication, aligning their practices with contemporary trends and pioneering novel construction methods.
Figure_19_Design Experiment (source - google)
Figure_20_Digital Fabricated models and tools (source: arch daily)
3.2 Adapting Nature and Gothic Architectural Strategies into Contemporary Design
3.2.1
Incorporating Computational Techniques and Artificial Intelligence in Furniture Design - Bench
In the exploration of contemporary design, the incorporation of nature and Gothic architectural strategies presents an intriguing avenue. Within this context, a specific focus lies on the amalgamation of computational techniques and artificial intelligence to inform bench design. This innovative process entails extracting elemental components from the intricate designs found in Gothic architecture and the organic beauty of nature and infusing them into the realm of artificial intelligence. This union results in an exploration of form and function that transcends the limitations of traditional design methods. By harnessing the capabilities of artificial intelligence and computational design, architects and designers gain a transformative tool that allows them to iterate, simulate, and optimize designs with unparalleled precision and efficiency. This approach not only accelerates the design process but also opens doors to previously unattainable intricacies in form, pushing the boundaries of what is possible. Moreover, it nurtures a harmonious synergy between the natural and the architectural, fostering the creation of furniture that not only embodies aesthetic appeal but also resonates with the structural integrity found in the organic world. In essence, the integration of artificial intelligence and computational design in the exploration of form is a gateway to innovation, enabling designers to draw inspiration from the past, the natural world, and contemporary technology to shape a more sustainable, visually compelling, and functionally efficient future.
• Created variation of surfaces following the symmetry with the use of Artificial Intelligence - Mid Journey from the model shown here
• Repetation of pattern
• Different construction of vaults.
• Base coloumns.
This chapter delves into the integration of robotic construction techniques within the field of architecture, with a specific focus on the utilization of clay megablocks as the primary construction material for the envisioned architectural structures. Clay, esteemed for its versatility and sustainable properties, emerges as an ideal choice for the proposed constructions. A particularly intriguing concept explored in this chapter revolves around the application of Voronoi patterns as a foundational design tool for crafting an array of architectural components, spanning from landscape elements and benches to affordable housing units and pavilions. Voronoi, a mathematical concept rooted in spatial division, facilitates the generation of intricate, interlocking patterns that seamlessly intertwine with the 3D modeling process. By harnessing the boundless potential of clay megablocks and marrying it with the versatile design capabilities offered by Voronoi patterns, architects are poised to unlock a realm of architectural possibilities, thereby blurring the boundaries between artistry, functionality, and sustainability within the structures of the future. The journey commences with the utilization of Voronoi patterns in a modest bench design and extends to the grand urban scale of Croydon Town in London, United Kingdom, where the same concept is applied to revolutionize architectural paradigms.
Figure27_Components Design through Autodesk Maya_Author
Figure26_Components Design through Autodesk Maya_Author
3.3 Incorporating Computational Techniques and Artificial Intelligence in the Croydon Town Center Project - Housing Systems
The incorporation of computational techniques and artificial intelligence into the Croydon Town Center Project, with a focus on housing systems, heralds a groundbreaking era in residential architecture. Building modular and sustainable homes, the design process is enriched by the integration of Voronoi patterns and computational methodologies. These advanced tools empower architects to craft structures with unprecedented intricacy and efficiency. Moreover, the inclusion of midjourney artificial intelligence (AI) for conceptual designs infuses the creative process with intelligent, data-driven decision-making. This fusion of innovation revolutionizes the approach to residential architecture, fostering the creation of not just homes but sustainable living environments that embrace the principles of eco-consciousness and technological progress. In the context of the Croydon Town Center Project, it paves the way for a harmonious, futuristic urban landscape that resonates with aesthetic appeal and environmental responsibility, setting new standards for contemporary housing.
Figure28_Components design achieved from the design done for the bench to create an housing system out of the same component (source: Midjourney - Artificial Intelligence)
3.4 Design Development for Housing Systems
The incorporation of computational techniques and artificial intelligence into the Croydon Town Center Project, with a focus on housing systems, heralds a groundbreaking era in residential architecture. Building modular and sustainable homes, the design process is enriched by the integration of Voronoi patterns and computational methodologies. These advanced tools empower architects to craft structures with unprecedented intricacy and efficiency. Moreover, the inclusion of midjourney artificial intelligence (AI) for conceptual designs infuses the creative process with intelligent, data-driven decision-making. This fusion of innovation revolutionizes the approach to residential architecture, fostering the creation of not just homes but sustainable living environments that embrace the principles of eco-consciousness and technological progress. In the context of the Croydon Town Center Project, it paves the way for a harmonious, futuristic urban landscape that resonates with aesthetic appeal and environmental responsibility, setting new standards for contemporary housing.
Design of the modular housing started with hexagonal shape ;which has good abilit for adding and extension.
Figure_29_Concept for Modular Unit_Autodesk Maya
Giving height to the hexagon and bend it in certain height for the vertical repetition.
Adding curvature to the form making “ruled surfaces” which transfer loads in better way.
By mirroring the form on horizontal axis we get forms that complete eachother , positive and negative and because of that of steel could be reduced due to each neighboring sides can share same steel edge.
Returning a substantial portion of the ground floor area to the public realm and establishing a stronger connection between the building and its surroundings become pivotal objectives. This endeavor is underscored by the incorporation of balconies and green roofing, which collectively contribute to a sustainable and eco-friendly environment. The residential architecture landscape undergoes a revolutionary transformation as it embraces innovation. This transformation capitalizes on Voronoi diagrams and computational design techniques to refine spatial layout and optimize resource utilization. Within the realm of housing systems, clay,renowned for its abundance, environmental friendliness, and health-enhancing properties, emerges as a cornerstone material. Its application not only fosters a healthier living milieu but also mitigates carbon emissions. When contemplating the structural framework for a three to four-storey housing apartment in London, architects are presented with a selection of options, including timber, steel, and reinforced concrete. Among these alternatives, timber assumes a prominent role, aligning seamlessly with clay due to its sustainability, versatility, and robust structural integrity.
Figure_30_Concept Diagrams for Modular Unit_Autodesk Maya
Figure_31_Concept Diagrams for Modular Unit_Autodesk Maya
Initiating a transformative shift in residential architecture, the design philosophy of the three-storey modular housing apartment places a strong emphasis on sustainability and eco-friendliness. The architectural innovation at play integrates sustainable materials such as clay, steel, and glass to create a harmonious blend of modernity and environmental consciousness. Clay, a locally abundant resource, serves as the foundational material in this endeavor. Utilizing cutting-edge clay 3D printing technology, the construction process is streamlined by fabricating modular components off-site. These clay parts are intricately designed to interlock, ensuring structural integrity and enabling swift assembly on location. The result is a reduction in construction time, waste, and energy consumption, aligning with the project’s eco-conscious goals. In addition to clay, steel and glass components are thoughtfully incorporated into the design. Steel framing offers structural support and stability, contributing to the building’s robustness. The integration of glass elements, strategically positioned to maximize natural lighting and ventilation, enhances energy efficiency and creates a seamless connection between indoor and outdoor spaces.
Furthermore, the commitment to sustainability extends to the overall design approach. Balconies and green roofing not only promote a healthier living environment but also contribute to a more sustainable urban landscape. The introduction of these green spaces aids in mitigating urban heat islands and enhances the quality of life for residents.
Figure_32_Rendered view of the housing systems designed from the component achieved from Gothic Architecture and Vornoi - Nature
A brief design and construction process of taking wet clay and turning into a finished and robust piece.
Figure33_Types of Clay 3D Printers_Clay Guide
Figure34_Process of Clay 3D Printing_Clay Guide
Figure35_Process of Clay 3D Printing_Clay Guide
The construction process of the housing model, elevated to full-scale reality through the synergy of computational design modeling and clay 3D printing, embodies a transformative approach to traditional building methods. Computational design modeling assumes a pivotal role in this progressive procedure, facilitating the inception of intricate and refined designs. Powered by sophisticated software, architects and engineers harness the potential to fashion complex geometries, assess structural soundness, and fine-tune material usage. Employing algorithms and parametric design, the housing model can be tailored with precision, factoring in various considerations, such as functionality, aesthetics, and sustainability. Once the design reaches its zenith, the spotlight shifts to the clay 3D printing process. This cutting-edge method allows for the methodical and automated layering of clay, materializing the design with unparalleled accuracy and efficiency. Guided by the digital model, the 3D printer meticulously deposits clay layer by layer, ensuring minimal wastage and meticulous material distribution, thereby enhancing the overall sustainability of the construction process.
The orchestration of logistics within this construction process is thoughtfully executed to ensure a harmonious operation. From sourcing locally available clay to its preparation for 3D printing, every facet is meticulously orchestrated. The transport and storage of the clay material, as well as the operation of the 3D printer, are seamlessly coordinated to optimize time and resources. This harmonious fusion of computational design modeling and clay 3D printing not only enhances the efficiency of the construction process but also broadens the horizons of architectural design. The once-elusive feats of intricate detailing, complex forms, and customizations are now readily attainable with grace, marking a watershed moment in architectural innovation.
In summation, the construction process of the housing model marries the capabilities of computational design modeling and clay 3D printing, resulting in an amalgamation of advanced technologies that births meticulous designs, precise material distribution, and streamlined logistics. The end product is a construction process that is not only efficient and eco-conscious but also propels architectural boundaries into uncharted territories.
Figure36_3D Printers used for the experimentation of Computational practices_Pinterest
Layer Heights:
When embarking on your design or slicing process, it’s crucial to consider the relationship between the nozzle size and the corresponding layer height. Inadequate attention to this factor can lead to complications in your clay 3D printing. If your layers are too high in comparison to the size of your nozzle, the clay may fail to bond correctly. Conversely, layers that are too small run the risk of over-extrusion, where an excessive amount of clay is pushed on top of each other, potentially resulting in clogging or compromising the quality of your prints. Refer to the following guidelines for recommended layer heights based on the nozzle sizes available at the DFL 4.3.4: File Preparation:
Much like our plastic 3D printers, the process of printing on clay 3D printers necessitates the use of an .stl file. This file format can be generated in most 3D modeling software. Look for the export button and select .stl as the file type. While we recommend Fusion 360 as our preferred 3D modeling program, other software options such as Solidworks, Rhino, or even Tinkercad are also suitable for creating .stl files.
Design Considerations:
Wall Thickness:
In the context of clay extrusions, the thickness of the extrusion determines the wall thickness of your print. You shouldn’t specify a wall thickness when designing your clay model for 3D printing, as this may lead to your slicing software attempting to print both the inside and outside walls. Typically, only one wall path needs to be defined when modeling for these machines, with the slicing software allowing for the adjustment of wall thickness to be double, triple, or thicker, if necessary. By default, the extrusion or group of extrusions will be centered on the path you’ve drawn.
Holey Files:
The quality of your print is greatly influenced by the quality of your file. A well-drawn file will result in a cleaner clay print. Ideally, your design should be continuous, without any holes, and possess a consistent shell of surfaces. While slicing programs have made significant improvements in handling these issues, not all 3D files will slice perfectly.
Support:
In many cases, it’s not feasible to print support structures for overhangs using slicing programs in clay. To address this, you may need to modify or add support shapes to your 3D model. For example, when printing a portrait, the chin may protrude too far for the layers to build outward. In such cases, consider creating a small, 45-degree wedge under the chin in your modeling software. After the print is complete and the clay has stiffened, you can remove the wedge.
Clay Consistency:
Achieving smooth prints and ensuring a hassle-free loading process for your tubes hinges on maintaining the right consistency of clay. It’s essential to note that the ideal clay consistency may vary depending on the specific 3D printer you’re using. Therefore, adjusting the clay’s consistency according to the printer’s requirements is vital for successful printing.
Figure37_Variation of nozzle size_Clay Guide
4.3 Achieving Production Accuracy with Modern Clay Manufacturing Techniques
Achieving production accuracy with modern clay manufacturing techniques, particularly through clay 3D printing, marks a significant advancement in architectural practices. Traditional methods of clay construction often relied on manual craftsmanship, which, while imbued with artistry, carried inherent variations in form and precision. Clay 3D printing introduces a level of accuracy and consistency previously unattainable. By leveraging computer-aided design and automated printing processes, architects can meticulously control the dimensions and intricacies of each component, ensuring that they fit together seamlessly during assembly. This precision minimizes errors, reduces material waste, and streamlines the construction process. Moreover, the reproducibility of 3D printing allows for the creation of intricate, custom-designed architectural elements with unparalleled accuracy. As a result, architects can push the boundaries of design, crafting complex and sustainable structures that harmonize precision, innovation, and eco-consciousness in perfect alignment.
4.4 Geometric Customization as a Design Tool in Contemporary Architecture
Geometric customization stands as an indispensable design tool in contemporary architecture, especially when harnessed in conjunction with innovative techniques like clay 3D printing. This dynamic approach empowers architects to transcend conventional design constraints, offering limitless possibilities for intricate and customized architectural elements. With clay 3D printing’s precision and material flexibility, architects can craft geometrically complex structures and components with ease. Whether it’s the creation of unique facade patterns, ornate interior detailing, or personalized furniture pieces, geometric customization through clay 3D printing grants architects the freedom to infuse their designs with a distinct visual language. This level of customization not only enhances the aesthetic appeal of architectural spaces but also contributes to a deeper connection between the built environment and its inhabitants, ultimately redefining the boundaries of contemporary architectural expression.
5.1 Testing and Prototyping at Small Scales with Implications for Large-Scale Implementation
5.5 Modifications and Fittings in Clay-Based Architectural Solutions
6.2 Small-Scale Testing and Large-Scale Implementation
The process of experimenting with and incorporating Voronoi components through clay 3D printing technology offers a flexible approach for creating practical structures, ranging from benches to pavilions and housing systems, within the urban fabric of Croydon Town.
The journey commences with an extensive testing phase, often commencing with the development of a smallscale prototype, typically a bench. The Voronoi component, characterized by its intricate cellular network, bestows both structural integrity and visual appeal to the design. This initial testing allows for meticulous refinement, ensuring optimal material distribution and superior structural performance.
Upon the successful testing and refinement of the bench prototype, the next phase involves scaling up the same Voronoi component for pavilions and housing systems. Drawing from the principles and parameters perfected during the bench prototype stage, the Voronoi component is elegantly scaled up to accommodate larger structures while preserving both its structural robustness and visual coherence.
Clay 3D printing technology plays a pivotal role in materializing these visionary structures. The additive manufacturing process enables precise deposition of clay layers, meticulously replicating the intricate Voronoi pattern with pinpoint accuracy. The automated nature of 3D printing ensures uniformity and efficiency in material application, thereby reducing waste and optimizing resource utilization.
The implementation of the upscaled Voronoi component in pavilions and housing systems throughout Croydon Town offers a multitude of advantages. Firstly, the Voronoi pattern introduces a visually captivating design aesthetic that enhances the urban environment. Its inherent structural properties bestow these structures with resilience and stability, ensuring their longevity and safety.
Furthermore, the use of clay as the primary 3D printing material aligns seamlessly with sustainability and environmental considerations. Clay stands as a local, natural resource, reducing the carbon footprint associated with material transportation. Moreover, the additive manufacturing process reduces material waste, promoting a more sustainable approach to construction. In conclusion, this innovative integration of Voronoi components and clay 3D printing represents a significant step forward in scalable, eco-conscious, and aesthetically pleasing structural design for the urban landscape of Croydon Town.
Figure38_Testing the components with various fixing methods and materials_Author
5.2 Tool Path Design Utilizing Grasshopper and Cura
The incorporation of path systems in clay 3D printing, facilitated by software platforms such as Grasshopper and Cura, carries notable significance for several compelling reasons. It affords meticulous control over the 3D printing process, guaranteeing the precise deposition of clay layers. These path systems also introduce the opportunity to integrate diverse materials and forces, thereby augmenting the inherent properties of clay. Moreover, the capacity to subject multiple sectional models to software simulations empowers designers to gain valuable insights into clay’s unique characteristics and refine the final design for optimal performance. In summation, the utilization of path systems in clay 3D printing represents a pivotal advancement, enabling precision in control, material experimentation, and iterative testing, all of which collectively contribute to superior outcomes in construction projects.
Figure40_Experimenting different sectional grids for Clay 3D Printing_Clay Guide
Figure39_Experimenting different sectional grids for Clay 3D Printing with the help of Cura_Author
5.3 Managing and Ensuring Availability of Varied Sizes
Managing and ensuring the availability of varied sizes in contemporary clay construction is a multifaceted endeavor that draws upon the fusion of technology and logistical acumen. With the introduction of clay 3D printing and other advanced techniques, architects and construction teams are no longer constrained by the limitations of traditional manufacturing processes. This newfound flexibility allows for the creation of customized clay components in a wide range of sizes, tailored to the specific requirements of a project. To manage this diversity effectively, a meticulous approach to logistics and quality control becomes paramount. Ensuring a seamless transition from the digital model to the physical structure relies on precise coordination between the 3D printing process and on-site assembly. Additionally, a stringent quality assurance protocol safeguards against inconsistencies in size, guaranteeing that each component aligns flawlessly with its counterparts. This harmonious marriage of technology and logistics in managing size variations not only streamlines the construction process but also underscores the transformative potential of contemporary clay construction.
5.4 Transportation Considerations in Contemporary Clay Construction
Transportation considerations play a pivotal role in the realm of contemporary clay construction, given the shift towards off-site 3D printing of clay components. The logistics of moving these prefabricated elements to the construction site demand meticulous planning to optimize efficiency and minimize environmental impact. Choosing transportation modes that align with sustainability goals, such as low-emission vehicles, helps reduce the project’s carbon footprint. Additionally, considerations extend to the handling and protection of delicate clay components during transit, safeguarding against potential damage. Coordinated schedules and communication between suppliers, transporters, and the on-site team are crucial to ensuring a smooth process. In sum, transportation considerations in contemporary clay construction exemplify the overarching commitment to eco-consciousness and efficiency that characterizes this innovative approach to architecture.
5.5 Modifications and Fittings in Clay-Based Architectural Solutions - Process
Figure42_Experiment with different outer wall
Figure43_Process of Clay Manufacturing
Figure45_Use of R10 nuts and bolts to firmly connect the two parts together.
Figure46_Final connection outcome
Figure44_Placement of rubber washer in between the clay to avoid them touching.
Figure47_Final
3D Printed Clay
18mm thick
Recycled Steel
Slab
Figure48_Plan of one single component of the housing systems
Figure49_Joinery Detail for the component
Figure50_Housing Key plan and view
Figure51_Rendered Joinery Details of the component
The proposal for Clay 3D Printed Modular Housing Components presents a visionary approach to architectural construction, drawing inspiration from nature, Gothic architectural elements, and the efficiency of digital fabrication. This innovative housing concept encompasses the construction of modular Voronoi-inspired housing units, ranging from three to five storeys, featuring one or two-bedroom apartments. The central tenets of this proposal are sustainability and the utilization of cutting-edge materials. While clay, as a construction material, has been successfully experimented with on a smaller scale, this proposal aims to scale it up, combining it with steel and glass to enhance structural strength and aesthetic appeal. The incorporation of 3D printed clay, steel, and glass components aligns seamlessly with the ideals of modern architecture.
In the context of the construction, the dimensions of the glass elements are meticulously selected to balance energy efficiency and aesthetics, utilizing high-performance, double-glazed glass with low emissivity coatings. Sustainable steel components are crafted from recycled or reclaimed materials to minimize the ecological footprint of the construction.
Assembly on-site is facilitated by the modular nature of the components. The clay 3D printed elements, manufactured with precision off-site, are designed to interlock seamlessly, enabling swift and accurate assembly. These modular components are transported to the site and then assembled like a prefabricated puzzle, reducing construction time and enhancing efficiency. This approach not only optimizes the use of resources but also demonstrates the seamless integration of traditional and cutting-edge construction methods, ultimately realizing the vision of sustainable, innovative, and aesthetically captivating housing components.
6. CONCLUSION
In summation, the exploration of clay as a foundational building material in the architecture of the future unfolds as a vibrant avenue for innovation and sustainability. This essay has meticulously scrutinized various dimensions of clay, from its historical significance to its contemporary applications, integrating cutting-edge technologies like 3D printing and artificial intelligence. Remarkable architectural exemplars, ranging from ancient mud skyscrapers to the Tecla House and Mexico’s 3D printing and recycling pavilion, have been prominently featured, underscoring the extensive potential that clay holds in modern construction.
Furthermore, an all-encompassing comparative analysis has underscored the remarkable advantages of clay utilization. This natural material is celebrated for its eco-friendliness, cost-effectiveness, and time efficiency, positioning it as a sustainable cornerstone in construction. The exploration of clay 3D printing techniques has illuminated the intricate technical considerations and intricacies vital for successful implementation.
Moreover, the integration of computational design and artificial intelligence within the context of Croydon’s housing and urban development furniture showcases the potential for heightened functionality and enriched user experiences within clay-based structures. The essay has delved into critical aspects of construction logistics, encompassing testing, tool path design, size adaptability, transportation, and flexibility for modifications and fittings, thus ensuring the pragmatic applicability and long-term viability of clay as a building material.
In closing, the potential of clay megablocks stands as a beacon of transformation within the architectural landscape, offering sustainable, customizable, and aesthetically pleasing solutions. With continued research, development, and integration, clay-based structures can chart the course towards a more robust and sustainable built environment, seamlessly intertwining the tapestry of history with the limitless possibilities of the future.
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6. Amir Amjad Mohammadi, T. I. A. U., 2019. The geometric design of a masonry lattice space dome titled KARBANDI in Persian architecture. Sage Journal, 34(1-2), pp. 22-39
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23. Claypool, M. (2021). The Digital in Architecture: Then, Now and in the Future. Retrieved from space10: https://space10.com/project/digital-in-architecture/
