Adaptive cross-panel system: digital fabrication for freeform architecture

UNIVERSITÀ DEGLI STUDI DI NAPOLI “FEDERICO II” DIPARTIMENTO DI ARCHITETTURA

CORSO DI LAUREA MAGISTRALE IN ARCHITETTURA TESI DI LAUREA IN TECNOLOGIA DELL’ ARCHITETTURA

ADAPTIVE CROSS-PANEL SYSTEM: TECNOLOGIA COSTRUTTIVA PER IL FREEFORMING

Relatore

Candidato

Prof. Arch. Sergio Pone

Ruben Agostino Matricola N14001998

Anno accademico 2018/2019

DON’T PANIC.

INDEX

Chapters

pag.

Intro

9

Abstract

11

01 - State of the art

17

02 - The Moge International Workshop

43

03 - Case study

77

04 - A new constructive system

87

05 - Generative Design

107

06 - Production

125

Renders

137

Acknowledgements

153

9

10

Intro

This volume aims to guide the reader through the path I faced during my thesis research, allowing him to know and understand my decision-making process.

In the last phase of reorganizing the material I used, I ran into the problem of how to share this information in the most effective way.

For this purpose, given the nature of the covered topics, such as algorithmic programming and modeling, I decided to use a more approachable and immediately understandable means of communication: pictures.

Visual representation is a key element in the architectural discipline, and the language by which the architect manages to give life to his ideas and then communicate them.

In 2020, this research saw new addition published in the 2020/2021 IASS - International Association for Shell and Spatial structures symposium. https://www.researchgate.net/publication/354068488_Adaptive_cross-panel_system_digital_fabrication_for_freeform_architecture

11

12

Abstract

Free-form surfaces are getting an increasingly important role in contemporary architecture, infact, the design and construction of free-form architectural structures represents a process consisting of two dynamics: form and static/technological rationality.

The aim of this thesis is to develop an innovative technological solution that can combine form-finding processes with important aspects of function and manufacturing in line with designers’ intentions.

13

FORM

Armadillo Vault, ETH Zurich - Venice Biennale 2016

14

STATIC/TECNOLOGICAL

RATIONALITY

15

Freeform ...

Freeform: “not conforming to a regular or formal structure or shape”.

It represents a wide range of geometries that do not rely to Euclidean rules, preferring complex, plastic and fluid morphologies.

The birth of freeform design has had, in recent years, a strong impulse thanks to the introduction of 3D modeling software, which have simplified the operations of managing geometries of such complexity.

16

... Structures

Experimentation in the structural field already began in the first half of the 1900s.

Eduardo Torroja, Le Corbusier, Oscar Niemeyer; are just some of the architects who have explored this field, creating incredible architectures. In Italy we remember Sergio Musmeci and Pierluigi Nervi.

The first freeform structures were made of reinforced concrete, mainly to overcome the problems in the creation of smooth continuous surfaces.

15 17

18

01

STATE OF THE ART

19

Building Evolution

«The history of building evolution demonstrates that the transformations of construction technologies have always had the aim of reducing the absolute cost, that is, to achieve technical and economic advantages by innovating the construction process and/or to provide, with new types, qualitative improvements in functioning performances towards users.»

(Prof. Ing. Michele Pagano)

STONE - TRILITHIC SYSTEM A construction system dating back to the dawn of humanity, it consists of two vertical elements, piers, and a horizontal one placed at the top, architrave.

The Greeks used exclusively the architrave system, with dry stone.

The elements were obtained from huge blocks of stone, which were transported on site, processed and finally raised to the desired position for the anchoring using iron clamps.

Given the poor shear and bending strength of the stone, only small lights could be covered.

20

21

22

BRICK - ARCHIVOLT SYSTEM The introduction of a regular, manageable and industrial element allowed the Romans to solve the problem of covering large spans by perfecting the arch.

It was now possible to use a single modular component for the construction of entire structures, joining each brick with cement mortar.

The hardenig of the mortar allowed the bricks to be bonded, creating a single structural element that was much more resistant.

23

STEEL In the second half of the 19th century, with the introduction of new techniques for refining cast iron, it was possible to obtain steels with excellent physical-mechanical properties, allowing its use in the structural field.

The use of steel has led to innovations not only in construction techniques but also in the architectural language.

Its structural use was refined again by Mies Van de Rohe, with the use of standardized and modular elements.

24

25 23

26

REINFORCED CONCRETE The first uses of caementum date back to the Roman age, where it was mainly composed of pozzolana and lime.

But it is thanks to the experiments of François Hennebique, in the second half of the 19th century, that steel bars were introduced to increase their traction strength.

The first to understand the potential of the Systéme Hennebique were Auguste Perret and his pupil Le Corbusier.

The latter raised the reinforced concrete to the material of modernity, using it mainly for the realization of his works.

27

New Needs and Opportunities «Sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs.»

World Wide Web

19 95

19

87

Brundtland Commission

During the last decades it has been noticed that, with the achievement of technical-economic advantages and qualitative improvements, new needs and opportunities have risen, represented by the sustainable development and the digitization of production processes.

Furthermore, it can be observed how this evolution, at first very slow, is now accelerating, making an in-depth analysis more and more difficult.

28

Microsoft releases Internet Explorer for its operating system: Windows 95.

German industrial plan for digital transformation.

The platform’s goal is to bring together its skills in relation to Industry 4.0 and make them available to german companies, in particular the small and medium-sized enterprises.

Sustainable Development

Plattform Industrie 4.0

20 11

20 00

TODAY

Digitalization of production processes

29

Sustainable Development

Green Building

30

Architecture must be compatible not only with human life and his activities but also with the natural environment and, more in general, with the context in which it’s inserted.

(Brundtland Commission)

In 2015, the UN adopted the 2030 Agenda entitled “Transforming our world”.

This document specifies the 17 Sustainable Development Goals, to be achieved over the next 15 years.

The 17 goals are far-reaching, each with detailed goals to achieve, but the World Green Building Council has identified a few of them where green buildings can contribute significantly.

31

Digitalization of production processes

Digital Fabrication

The digitization of production processes is the result of the advent of the 4th industrial revolution, promoter of a new interconnected and automated production.

In architecture this process is represented by Digital Fabrication, that is the transposition of digital artifacts into physical products through computer-assisted production.

32

This basically means, but not only, 3D printing, which however, is flanked by other methods such as laser cutting and numerical control milling (CNC) depending on whether “additive” or “subtractive” techniques are used.

Additive techniques consist of adding material layer by layer. Unlike conventional casting and forging techniques, where the material is poured into a mold and shaped, in this case the “negative” is the product file.

Subtractive production is, on the other hand, a production method that starts from a block or a sheet of a single material from which the superfluous parts are removed, by milling or turning.

33

With the introduction of digital technologies, there was a need to develop a new set of mental processes in order to approach them, represented by the

100 0110

Computational Thinking

«Computational thinking is the thought process involved in formulating a problem and expressing its solution(s) in such a way that a computer can effectively carry out.»

(Jeannette Wing, 2006)

It consists in solving problems, designing systems and understand the human behavior, using the fundamental principles of computer science technology.

It’s not about forcing humans to think like computers, instead computational thinking is about humans teaching computers how to solve problems.

34

It has the following characteristics: Integrates and combines mathematical and engineering thinking.

It draws on mathematical thinking, since, like all sciences, its formal foundations rest on mathematics.

It draws on engineering thinking, as we build systems that interact with the real world.

100 Affects ideas.

0110 We won’t interact only through the softwares

and the hardwares we’ll produce, but we’ll use computational concepts to face and solve problems, to manage our daily life, and to communicate and interact with other people.

It’s for everyone and can be used in all fields.

100 0110

100 0110

35

A kid‘s game

Cubetto

36

Cubetto is a play set designed to introduce children to computational thinking.

Children play with the “queue” of instructions, one of the fundamental concepts of coding, without using screens or words.

Cubetto is controlled via bluetooth by inserting sequences of action blocks in the slots of the interface panel.

Through the various shapes, indicating abstract directions, each block represents a specific action each of wich is brightly colored so not to be confused.

Children create a chain of sequential actions (the “queue”) by placing blocks on the board. A sequence of blocks is in fact a program, which Cubetto will execute.

37

Computational thinking

How it works ?

Thinking computationally means dividing the decision-making process into individual steps, thinking about the best way to achieve a goal.

In computer science this can be traced back to the algorithm, a simple procedure used to solve any given problem by applying a certain number of elementary steps/instructions, interpreted and executed in a precise order.

38

The computational thinking process can be divided into three stages:

1- Problem statement (Abstraction) The formulation of a question: ex. “How something works”; at this stage the use of the computer is not necessary to start the process, the problem can be visualized using, for example, a diagram on a piece of paper.

2- Expression of the solution (Automation) Unambiguous expression of the solution through computer programming, so that the computer can execute it.

3- Execution and Evaluation (Analysis) The execution of the solution by the computer shows the direct consequences of one’s thinking.

The three phases describe different relationships of human and IT responsibilities.

The execution of the solution is largely a computer’s responsibility, while the expression of the solution is attributable to humans.

Otherwise, the formulation of the problem, generally considered exclusively a human responsibility, appears to be the result of man-machine synergy.

39

Computational thinking

In Architecture

Ivan Sutherland using Sketchpad, 1963.

In architecture, computational tools have introduced innovative design and production architectural techniques, described as Computational Geometry.

In turn the combination of algorithmic programming and geometry has produced algorithmic geometries known as Generative Algorithms.

«Generative algorithms allow the user to design a process rather than a single object.»

(Arturo Tedeschi, Algorithms Aided Design, 2014)

40

Architectural design has undergone the influence of Generative Algorithms, translating it into a new high level of complexity.

In order to work with complex objects, the design process is divided into different levels; starting from the first, simpler, others are added, each containing different information.

These levels are interconnected, influencing each other.

We have therefore moved from an Additive Process (drawing), where each data is independent, to a new working method based on Associative Relations, represented by modern CAD, 3D modeling and parametric modeling software.

41

Systems

The novelty proposed by algorithmic design is the adjustability after the process.

Since the product design is the result of an algorithm, the inputs can be changed and the result can be updated accordingly.

It is therefore now possible to create the digital version of a model and generate hundreds of variations by adjusting the simplest geometric parameters.

(Hensel, Menges, 2008) 42

The process of morphogenesis to which they are subjected makes these systems Adaptable to any change, making them independent of the shape.

Adaptive Systems can therefore respond to the clear need to develop new technologies and strategies that describe the dynamics of contemporary architectural research.

Shipwreck variations, Arthur Mamou-Mani - Burning Man festival 2013

43

44

02

THE MOGE INTERNATIONAL WORKSHOP

45

The Workshop

Material Optimisation Geometric Exploration

46

The thesis research began concurrently with the MOGE International Workshop, held by the University of Naples Federico II and the École Nationale Supérieure d’Architecture de Paris-Belleville in February/April 2019.

The workshop aimed to explore the process based on computational thinking for the involvement of design strategies and production actions within a single digital development environment.

The ultimate goal was to design/build a small wooden panel pavilion.

The workshop saw two phases: the first in Naples for the design of the pavilion and the second in Paris for the construction phase.

47

Modular Box

In the first meeting we were assigned different constructive archetypes to explore, I chose the Modular Box system.

This archetype can be easily identified in LEGO bricks, designed to assemble with each other, being part of a system that connects them.

The concept of modular box, therefore, starts from a module that undergoes a reiteration and transformations in space, with the aim of generating a series of shapes defined by the designer.

48

49

Modular Box

Applications

BOXEL, Detmold University - 2010 Built at the end of a competition among the students of the Detmold School of Architecture and Interior Design, the pavilion, based on a minimal surface, consisted of 1950 crates of beer organized according to a free-form geometry.

The usual vertical stacking of boxes was abandoned, preferring a free organization.

The geometry has evolved from three support points forming three arches that look towards the main buildings of the Campus.

Note rapide Pagina 2

Note rapide Pagina 3

50

SERPENTINE PAVILION, BIG - 2016 The structure built near Kensington Gardens in London is entirely made up of translucent fiberglass boxes, superimposed on each other in a typical brick pattern.

The hollow bricks gradually stagger back and forth to create two wavy surfaces, which divide to create curved entrances at both ends of the pavilion, leaving a large space in the center.

51

The Hive

The first pavilion hypothesis:

1 - The type of plan, a passage and a waiting space.

3 - The shape of the module, the hexagon.

2 - The static scheme, the wall.

4 - The connection systems, wood-wood through finger joints; wood-metal with the use of screws and bolts.

52

By building hexagonal cells that share walls, bees can better conserve their resources.

This geometry makes it possible to use a minimum amount of material maximizing space.

53 51

MODULE

AGGREGATION

COMPOSITION

54

finger joints

threaded rods

1

2

ground assembly

construction 55

During the design we realized that the assembly, and the subsequent aggregation of the modules, would have created a contact surface between them that would have doubled the thickness of the walls.

This would have resulted in the use of more material, increasing the weight of the structure and therefore the overall cost of the pavilion.

Furthermore, another problem to dealt with would have been the junction of the individual modules.

The honeycomb structure, in nature, represents a minimum density system that records relatively high compression/shear properties out of its plane, it would have been unthinkable not to exploit these capabilities in our project !

For this reason we have set ourselves the goal of persevering along this path, minimizing the amount of material used by avoiding the doubling of the sides.

56

The resolution of this problem has seen, therefore, the formulation of a second hypothesis.

This has the same workflow as the first, up to the design of the connection systems, but with the introduction of extra elements:

57

The new hypothesis also involved the transition to a new archetype:

Cross-Panel System

This system consists of interlocking elements joined together and by varying the angle of the carvings it is possible to obtain numerous configurations.

58

MURO PIXEL, Universidad del Bío-Bío, Universidad de Concepción e Lasalle University Center Brasile - 2010

59

The new construction process, in fact, no longer provides for the aggregation of individuals hexagonal modules, but rather the interlocking of their individual panels.

60

The module is broken down into its elementary parts,

and these are then reconfigured to create the same initial composition, avoiding the doubling of the sides.

61

However, since the panels are no more orthogonal to each other, they cannot be connected by simply joining them together.

We therefore faced a new problem, designing a connection system.

?

62

The solution came to us by analyzing the structural scheme of the trusses.

These structures are composed of Rods, which distribute the forces, and Nodes, connecting the rods.

63

Elements hierarchization

By applying the same methodology to our project, we have identified the panels as the rods of the structure, while for the nodes we have designed from scratch a triangular-shaped connector element, which allows the joining of three panels.

64

NODE:

CONNECTOR

ROD:

PANEL

65

The modular coordination, therefore, is no longer created by the aggregation of the hexagonal modules, but instead by the joints that allow the panels interlocking.

66

This solution allows the same hexagonal configuration of the first design hypothesis, eliminating, at the same time, the doubling of the sides.

67

The null theory, the steel brick Modular design g

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68

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The theory was formulated during the experimentation of the steel brick, a modular element composed of molded sub-components.

The name, given to the system since its inception, derives from the fact that it was immediately realized that it was the refoundation, in modern terms, of the glorious terracotta brick.

(Michele Pagano, Steel 1988) According to Prof. Pagano, the industrial development of construction was experiencing a stagnation, represented by the production of complex components with a high pre-design content.

The solution would have been represented by the production of elementary modular components, free of function and/or conditioning of shape and material, the steel brick precisely.

The same Brick was a subject of my studies, inspiring the path taken in the technological solution used in the Moge pavilion.

69

Parametric Experimentation Having solved the technological problem, we moved on to the application phase, using parametric modeling.

The process starts from the surface,

this first undergoes a horizontal subdivision,

70

and then a vertical subdivision, identifying a grid of points.

Subsequently, the centers used to place the hexagons are chosen from these,

finally, they are extruded to create the modules of the pavilion.

71

Final draft

72

73

74

75 73

How does it beehaves?

The end of the workshop saw the identification of the limits of this construction system.

In the first place, the system works by gravity and not by contrast of the elements, resulting in the creation of a single possible static system, the wall.

Secondly, in order to discretize more complex surfaces, it was necessary to reduce the size of the elements, increasing the number of hexagons, this involved the use of more material which made the construction phase and subsequent assembly more difficult.

My research has seen the resolution of these two problems, resulting in a new technological system.

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03

CASE STUDY

79

Neowa Dome

The research continued in Naples, and in this phase, my attention focused on the pavilion designed by Kengo Kuma for the Asian Cultural Center in Gwangju: Neowa Dome.

Neowa is a Korean word that means “wooden board cut with an ax”, where the boards are the element used for the construction of traditional Korean houses.

80

The idea behind this project was to build a light and flexible “house” with a modular element, this is achieved thanks to the use of plug connections with which it is possible to assemble and disassemble the pavilion with ease.

81

“Pinning” consists in joining the pieces through wooden pins. This methodology is mainly used for coplanar-tip joints and T connections, but also for corner joints.

The pins, in this case cylindrical and ribbed, are inserted into holes, blind or through-holes, made on the two pieces.

It’s very important to consider the right diameter of the pins, and therefore of the holes, which must be well sized to avoid weakening the piece (in the case of an excessively large diameter) or not being sufficiently solid (otherwise).

82

83

In the case of the Neowa Dome the panels lie on a plane orthogonal to the ground, superimposed and projecting, supported by gravity and not by contrast; the dowels are hidden, that is, inserted inside the panels, giving the impression that the whole structure is in balance.

84

85

New optimization strategy

This triggered an intuition in me, that of eliminating the dowel element and using only the panels, which would now perform both as connecting and node elements, thanks to the use of interlocking connections.

This resulted, in my research, in a new optimization strategy that no longer provides for the hierarchization of structural elements.

86

By eliminating the nodes, I therefore reduced the number of elements to be used for construction and laid the foundations for the design of a new constructive system.

87

88

04

A NEW CONSTRUCTIVE SYSTEM

89

Static scheme

The second problem to be addressed has beenthe static scheme.

As previously shown, both the Neowa Dome and Hive make use of the “false dome” system, the elements are superimposed on each other and protruding progressively.

This is due to the position of the joints, orthogonal to the ground.

90

91

Orthogonality is the key feature of the halved joint, as it represents the simplest example of wooden joint.

Each panel has half-wood nothces in which a dowel, that is exactly half the thickness of the joint, is removed on both pieces. In this way, once the two boards are joined, the contact surface will be equally distributed between them.

Cuts that are perpendicular to the panel perimeter, however, allow only 90° connections between the two pieces.

For this reason I had to adapt this technique to my needs.

92

KODAMA, constructive system designed by Kengo Kuma for the Kodama pavilion - 2018

93

The solution

The solution adopted, simultaneously the elimination of the node element, was to move the joint from an perpendicular position to the panel perimeter to a variable one.

By varying the notch angle in only one direction, the elements can be used to create archivolt systems.

94

If the angle is varied in both direction, instead, the possible configuration multiply and the system can be applied to discritize freeforms.

95

However, the halved joint does not ensure a solid and robust connection. This is the consequence of the small contact surface distributed among the panels. This causes the joint to be subject to twisting moments along the notches axis, the system is thus weak and subject to cracks.

It is therefore advisable to use glue and/or screws to stiffen it and further fix the two elements together.

To sort out twisting problems, it has been necessary to design a reinforced version of the halved joint

96

It was done by doubling the panels in both interlocking directions.

The juxtaposition of two panels, parallel to one another. has made it possible to double the contact surface and, consequently, increase the torsional strenght and stability of the components.

This solution has been chosen to avoid the use of glues and/or screws, in order to simplify the assembly and dissasembly of the elements, thus making the system reversible.

97

98

99

The doubling of the panels makes the new system the result of the two constructive archetypes previously illustrated: Cross-panel and Modular box

The type of joint derives from the first, while the second can be identified in the decomposition of the system into its elementary parts.

100

101

The system thus designed is now required to meet the requirements of the Green Building.

Goals Energy Consumption Reduction Industrial processes involved in architecture, must have the least possible impact on the environment, using renewable energy sources where possible.

102

Reversibility The architectural work must be easy to assemble/disassemble, in such a way as to “leave no traces”.

Recycling and reuse Provide for the reuse of waste materials from industrial production for the manufacture of building components.

103

The material of choice was therefore wood, which perfectly expresses the demands for sustainability.

Strategies Energy Consumption Reduction Studies confirm that wood is a material with better performance than steel or concrete in terms of embodied energy, air and water pollution and greenhouse gas emissions.

600% 500% 400%

wood steel

300%

concrete

200% 100% 0% air pollution

104

solid waste

resource use

energy

global warming potential

water pollution

Reversibility It favours dry construction systems without the use of binders allowing the design of no-invasive buildings.

Riciclo e riuso The wood industry reduces waste thanks to production optimization and the scraps reuse in the supply chain.

105

Optimization Imput

CONSTRUCTIVE SYSTEM NEGATIVE

FORM FINDING

SURFACE

FITNESS Optimization

STRUCTURAL SIMULATION POSITIVE

Output DESIGNER’S REQUIREMENTS ARE NOT SATISFIED

ADAPTIVE MODEL DESIGNER’S REQUIREMENTS ARE SATISFIED

CAM* PROCESS *Computer Aided Manufacturing

Adaptive Systems requires that the entire constructive system can modify its configuration to the base-surface variations, accordingly to the structural analysis validation.

In fact, the design process includes an Optimization phase through Control Systems.

106

Fitness - Algorithmic modeling Process involving 3D modeling programs (Rinocheros) and programs to create Generative Algorithms (Grasshopper).

Structural simulation Parti deboli della struttura

It relies on structural engineering programs such as Karamba, capable of working in conjunction with parameterized geometric models.

The research continued exploring the Generative Design via Rhinoceros/Grasshopper.

Structural simulation was not addressed, due to its complexity which would have required a separate research.

Forma finale della struttura

107

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05

GENERATIVE DESIGN

109

The process

In Generative Design the creation of the form is based on algorithmic laws, deriving from computational tools controlled by the user.

Algorithmic modeling has been made accessible and intuitive through “visual tools”, allowing new users to approach coding.

Grasshopper is a visual programming language.

Data flows from one component/control to another via “connection wires” that connect an output with an input socket.

110

However, these “definitions” can easly grow exponentially, becoming chaotic agglomerations of lines and nodes.

So, to simplify the understanding of the developed process, I decided to represent it conceptually through flowcharts, indicating step by step all the operations carried out.

START

1

2

FINISH

111

Surface

Rhino3D generates the network of curves used to obtain the double curved surface.

SURFACE

112

Meshing

In Grasshopper, the surface is transformed into a polygon mesh, that is, a discretization of a larger geometric domain by smaller cells.

SURFACE

MESH GENERATION

This is an important step, because the mesh subdivision affects the definition of the surface and the number of the elements in the final strcture.

113

Scaling

To obtain individual panels, each cell is scaled respect its center.

SURFACE

MESH GENERATION

SCALE

Planarize

The quadrangular mesh, howerver, is not made of planar cells.

To achieve this, the centers of the cells are projected onto the base surface in order to detect the tangent planes on those points.

114

Subsequantly, the scaled mesh cells are projected onto these planes, thus obtaining their planarization.

SURFACE

MESH GENERATION

SCALE

PLANARIZE

Offset

The last step is the offset to obtain the internal and external panels of the first frame, that is, the panels tangent to the surface.

SURFACE

MESH GENERATION

SCALE

PLANARIZE

OFFSET

115

First frame

SURFACE

MESH GENERATION

SCALE

PLANARIZE

OFFSET

Planarize

For the second frame the tool starts from the planarized cells perimenters.

SURFACE

116

MESH GENERATION

SCALE

PLANARIZE

Midpoints

The midpoints on each side of the cells are identified.

SURFACE

MESH GENERATION

SCALE

PLANARIZE

MIDPOINTS

Lines

The points are then joined, thus creating lines in both directions.

SURFACE

MESH GENERATION

SCALE

PLANARIZE

MIDPOINTS

LINES

117

Extend

The lines arethen extended in order to generate orthogonal planes to the surface.

MESH GENERATION

SURFACE

SCALE

The orthogonality between planes is an essential condition, not met in a first definition, where the panels of the second frame were identified through the extrusion, along the normals of the surface, on the perimeters of the cells.

1

> 90°

2

This need is due to the fact that three-axis laser cutting machines allows only perpendicular cuts to the working surface; therefore, the notches will all be at 90°, making joints at variable angles difficult.

118

PLANARIZE

MIDPOINTS

EXTEND LINES

LINES

Planes identification

1st direction

The identification of these planes allows the orthogonality condition to be respected between the panels of the first and second frame.

2nd direction

SURFACE

MESH GENERATION

SCALE

PLANARIZE

MIDPOINTS

ORTHOGONAL PLANES

EXTEND LINES

LINES

119

In detail, only the XY angle must comply with this condition, the XZ and YZ angles can vary allowing the correct fitting of the elements to the surface, creating a flexible and sef-supporting system.

Z

X Y

120

Extrusion

The lines are extruded along the orthogonal planes.

SURFACE

MESH GENERATION

SCALE

PLANARIZE

MIDPOINTS

EXTRUSION

ORTHOGONAL PLANES

EXTEND LINES

LINES

Offset

At last a offset is made to identify the panels of the second frame.

SURFACE

MESH GENERATION

SCALE

PLANARIZE

MIDPOINTS

OFFSET

EXTRUSION

ORTHOGONAL PLANES

EXTEND LINES

LINES

121

Second Frame

SURFACE

MESH GENERATION

SCALE

PLANARIZE

MIDPOINTS

OFFSET

EXTRUSION

ORTHOGONAL PLANES

EXTEND LINES

LINES

Join

The last part of the tool is dedicated to the creation of the carvings.

The surfaces are joined.

JOIN

122

Intersections

The intersection lines between the panels are identified.

JOIN

INTERSECTIONS

Carvings

With the “Rslits” command, thicknesses and tolerances are decided.

JOIN

INTERSECTIONS

CARVINGS

123

Final Draft

JOIN

CARVINGS

INTERSECTIONS

Complete definition FIRST FRAME

SURFACE

MESH GENERATION

SCALE

PLANARIZE

OFFSET

MIDPOINTS

LINES

EXTEND LINES

EXTRUSION

ORTHOGONAL PLANES

SECOND FRAME

OFFSET

JOIN

FINAL DRAFT

CARVINGS

124

INTERSECTIONS

125

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06

PRODUCTION

127

Building details

The last part of the research has been focused on the design of thecnical elements: foundation and roofing.

These are not realized through parametric modelling, in order to adapt the structure to different climatic and territorial variables.

Therefore, the proposed solution is well suited to temporary pavilions characterized by durability and resusability.

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COPERTURA

ATTACCO A TERRA

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Foundation

Chipboard screw 80mm Ø5mm

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Roofing

Polycarbonate hollow sheet thk 10mm

Polycarbonate h-profile 73mm x 10mm

Chipboard screw 80mm Ø5mm + EPDM gasket + washer

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CAM process

CAM stands for Computer-Aided Manufacturing.

Through this last process I made a 1:10 scale model of the pavilion.

The same methodology can also be applied to a larger scale, in this case the machines used will be industrial.

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The production technique used has been the subtractive type, by means of a three-axis laser cutting machine avaible in our university.

The cut was preceded by a pre-production phase consisting of: nesting and labeling. These are necessary for a successful cut.

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Nesting

In digital fabrication, Nesting is the process of creating cutting patterns to minimize material waste.

OPENEST Is a grasshopper addon capable of unrolling, packing and numbering the elements.

The software analyzes the shapes to be cut, determining their arrangement on the sheet, thus minimizing the amount of wasted raw materials.

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1086 elements

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Labelling

Labelling process of the elements, to allow their recognition during the assembly phase.

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Cataloging

Construction

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SERPENTINE GALLERY, ALVARO SIZA - 2005

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SMITHSONIAN COURTYARD, FOSTER + PARTNERS - 2007

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NEOWA DOME, KENGO KUMA - 2016

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Acknowledgements

I primi ringraziamenti vanno ai miei genitori, i quali mi hanno sempre sostenuto e incoraggiato con sacrifici che difficilmente riuscirò a ripagare.

Ringrazio mia sorella Alice che di tanto in tanto passava per la mia scrivania con la gatta in braccio, riuscendo a strapparmi un sorriso anche nei momenti più frustranti.

Un ringraziamento ai miei fantastici 5, questi anni universitari non sarebbero stati gli stessi senza di voi: Ugo, con la sua compagnia e incredibile pazienza in ogni circostanza ( e no non mi riferisco a delle stanze da circo ); Federica, con il suo cinismo e irriverenza, è stata l’unica che è riuscita a tenere a bada me e Ugo tra risate e minacce ( mi scuso per l’infelice battuta di sopra ); Carla, con il suo sorriso portava il buonumore e un thermos di tè caldo ( un giorno ti prometto andremo tutti assieme a farci una pizza, un giorno ... forse ); Claudia, con il suo grande affetto e la tua voce mi ha insegnato due cose, vedere sempre il lato positivo della vita e ricordarmi ogni tanto di fare un esame audiometrico ( però adesso abbassa la voce ); Vincenzo, con la sua organizzazione e il fascino da DonGiovanni ( due cose sono infinite: l’universo e il numero di donne che conosci, ma riguardo l’universo ho ancora dei dubbi).

Ringrazio anche: Giovanna, Silvia, Caterina, Lidia e Francesca, Nicola, Giovanni, Davide, Daniele, Simone, Gabriele, Francesco, Giuseppe, Marco, Giusy, Antonella, Carlo, tutti i ragazzi con cui ho lavorato in questi anni.

Un ringraziamento corale a tutti i miei amici con cui ho condiviso serate, braciate e campagne di D&D, specialmente ad Alfredo per essere da sempre un amico su cui poter contare.

Infine vorrei ringrazie il Prof. Pone. Quando entrai per la prima volta nella sua aula non avrei mai pensato di legarmi così profondamente con un professore. In questi anni è riuscito a trasmettermi la passione e l’entusiasmo che lo caratterizzano in ogni situazione, che stia insegnando in un’aula universitaria o in un cantiere con un avvitatore in mano ad urlare ordini. È stato un onore e una fortuna incontrarlo e affrontare alla fine questo percorso di tesi sotto la sua sapiente supervisione. Grazie.

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So long, and thanks for all the fish.