BPro RC 5+6 2016/17_Clay Robotics - Manifold Assemblies

MANIFOLD ASSEMBLIES Digital Ceramic with Wood Structure for RIBA

Tutors: Daniel Widrig Guan Lee Soomeen Hahm Stefan Bassing Igor Pantic Adam Holloway TeAM members: Hao Li Wenyan Zhao Jialin Tang Xinnan Zhao Zizhuo Su Heyoung Um Jiawei Xi Xiangheng Min

CLAY ROBOTICS INTRODUCTION HAO LI, XIANGHENG MIN, JIALIN TANG, ZIZHUO SU,

HEYOUNG UM, JIAWEI XI, WENYAN ZHAO, XINNAN ZHAO Clay has been a widely used material for centuries as it is easily available, cheap, and plastic in application. This is especially true when clay is used in digital fabrication, as the digital extruding process makes non-standard designs possible to fabricate in a relatively easy and quick manner.

This shows the potential and ability for mass customization or “quick-prototypes”.

Industrial robotic arms have been widely used in architecture for many years, and work has been undertaken exploring the possibilities of automated fabrication in highly efficient and innovative ways in order to discover the potential of the materials in digital fabrication. When clay meets the robotic arm, the interaction between them is unstoppable.

The robotic arm at Grymsdyke Farm is a KUKA KR210, which can move in 6 different axes. However, at the present time, ceramic printing is always printed layer by layer; the extruder is basically used only perpendicular to the platform. The robotic arm has therefore not been taken full advantage of. Testing, designing, and printing ceramic components in ways that go beyond the layer technique is therefore the main subject of this study. One of the fabrication modes in which they are used is large-scale 3D printing. However, due to the limitations of the equipment, techniques, and materials, industrial robotic arm clay printing has remained relatively stagnant. Due to the innovation in robotic arm clay

printing, the projects this year have been achieved by the use of “Space” clay printing with support.

Clay could never be produced in as quick and solid in a way using existing technology, so the aim became to control the robotic arm to facilitate printing along with the support, letting the nozzle climb on the surface. An analogy for this would be people walking on the earth, who would always be drawn toward the centre of the earth due to the gravity. With this technique, a shell-shaped component could be achieved.

Thus, the robotic arm could be used to work in a freer way, and instead of relying on layer-by-layer texturing, other textures could be introduced.

This year, the group has four projects, including V&A Tiles, Funicular Clay Shingles, Catenoid Aggregates and Manifold Assemblies. For the V&A Museum project, more than 2000 tiles are produced by robotic arm, which is the first mass digital fabrication of clay. The Funicular Clay Shingles form the baseis for the following two projects. As for the Manifold Assemblies, the tridimensional clay components are combined with wood frame and fabricated by the method of CNC carving and slip casting. And the fourth one is printed by robotic technique to realize the actual 3D clay printing. With the development of the technique innovated, this group achieved the clay application and digital fabrication in the actual construction.

TABLE OF CONTENTS

01 CATMULL-CLARK SURFACE CONCEPT > component > printing > aggregation

02 PROJECT BACKGROUND > CONCEPT background > site introduction

03 WOOD STRUCTURE > sturcture design > growth distribution > structure installation

4

04 BATWING MINIMAL SURFACE > MINIMAL SURFACE COMPONENT > COMPONENT ASSEMBLING > COMBINATION OF COMPONENT AND STRUCTURE

05 FABRICATION > robotic printing > mold > slip casting > firing >installation

AD RC5&6 Clay Robotics | UCL

5

6

CATMULL-CLARK SURFACE CONCEPT > Component > Printing > Aggregation

AD RC5&6 Clay Robotics | UCL

7

CATMULL-CLARK SURFACE CONCEPT [COMPONENT]

Difference between Rectangle and Catmull Clark Surfacce

rectangular surface

Catmull–Clark surface

8

sharp shange angel

smooth shange angel

AD RC5&6 Clay Robotics | UCL

9

CATMULL-CLARK SURFACE CONCEPT [COMPONENT]

Component Variety cube geometry

curvey block

cube geometry

curvey block

10

AD RC5&6 Clay Robotics | UCL 11

CATMULL-CLARK SURFACE CONCEPT [COMPONENT]

Component Transformation

cube geometry

curvey block

cube geometry

curvey block

12

AD RC5&6 Clay Robotics | UCL 13

CATMULL-CLARK SURFACE CONCEPT [COMPONENT]

Dimension of Component

x=1, y=1, z=1

x=1, y=1, z=0.5

length: 300mm wideth: 300mm thickness: 300mm

length: 300mm wideth: 300mm thickness: 150mm

Max degree=70

14

Max degree=64

x=1, y=2, z=0.5 length: 300mm wideth: 600mm thickness: 150mm

Max degree=64

x=1, y=2, z=1 degree=66

x=2, y=2, z=1

length: 300mm wideth: 600mm thickness: 300mm

length: 600mm wideth: 600mm thickness: 300mm

Max degree=66

Max degree=56

x=2, y=2, z=2 length: 600mm wideth: 600mm thickness: 600mm

Max degree=70

AD RC5&6 Clay Robotics | UCL 15

CATMULL-CLARK SURFACE CONCEPT [PRINTING]

Printing Method

flat mold

16

mold with addition

nal holder

flat mold with white additional mold

AD RC5&6 Clay Robotics | UCL 17

CATMULL-CLARK SURFACE CONCEPT [PRINTING]

Printing Mold and Test

Layer two

Gap

Mold 2

Layer one Main mold

Layer two

Gap

Layer one

18

Main mold

01

01 Short Component length: 300mm wideth: 300mm thickness: 180mm 02 Long Component length: 300mm wideth: 600mm thickness: 180mm

long component length: 300mm wideth: 600mm thickness: 180mm

02

AD RC5&6 Clay Robotics | UCL 19

CATMULL-CLARK SURFACE CONCEPT [PRINTING]

Printing Mold and Test

FIRST TEST

SPEED OF ROBOT

30

MAXIMUN ANGLE OF ROBOT

20

FIRST LAYER HIGHT

4MM

DISTANCE BETWEEN LINES

5MM

MAXIMUM ANGLE OF MOULD

20

70

SECOND TEST

Perspective SPEED OF ROBOT

10

MAXIMUN ANGLE OF ROBOT

30

FIRST LAYER HIGHT

8MM

DISTANCE BETWEEN LINES

5MM

MAXIMUM ANGLE OF MOULD

70

Top view

AD RC5&6 Clay Robotics | UCL 21

CATMULL-CLARK SURFACE CONCEPT [PRINTING]

Printing Mold and Test

22

Perspective

Perspective

Top view

Perspective

THIRD TEST

SPEED OF ROBOT

15

MAXIMUN ANGLE OF ROBOT

30

FIRST LAYER HIGHT

9MM

DISTANCE BETWEEN LINES

5MM

MAXIMUM ANGLE OF MOULD

70

AD RC5&6 Clay Robotics | UCL 23

CATMULL-CLARK SURFACE CONCEPT [AGGREGATION]

Aggregation Logic

brick system

24

bounding box

rendering

AD RC5&6 Clay Robotics | UCL 25

CATMULL-CLARK SURFACE CONCEPT [AGGREGATION] Aggregation

26

AD RC5&6 Clay Robotics | UCL 27

CATMULL-CLARK SURFACE CONCEPT [AGGREGATION]

Aggregation Screen

28

AD RC5&6 Clay Robotics | UCL 29

30

PROJECT BACKGROUND > Concept > Site

AD RC5&6 Clay Robotics | UCL 31

PROJECT BACKGROUND [CONCEPT]

To celebrate UKGBC’s

10th Anniversary

Brief:

- A sculpture representing the values of the UK Green Building Council (UKGBC) to celebrate their

10th Anniversary.

- To be erected as part of a workshop with 12 members of staff from the UKGB at the Royal Institute of British Architects on Thursday 28th September - To be unveiled that evening at the 10th Anniversary event (ie. a one-day install) - To potentially be relocated (in parts or as a whole) to the offices of various members of the UKGBC

Budget:

£1000 research & development (samples, models, mock-ups)

£6000 final fabrication (materials, labour, transport, install, de-install)

32

timber, steel and clay. The fact that the timber is repurposed from Design Museum’s project, that the steel has been manipulated as little as possible to allow it to be re-used, Materially, the piece uses a simple palette of three materials:

and that the ceramic elements have been fabricated locally from British clay, are all secondary to the larger concept. Finding ways to limit material waste, financial excess, and resource consumption should be, as the UKGBC has phrased it, ‘second nature’ by now. Rather, what the piece seeks to champion is the ‘coming together’ – of materials, people, processes and ideas.

AD RC5&6 Clay Robotics | UCL 33

PROJECT BACKGROUND [CONCEPT]

What is the Ceramic and Pavilion?

Used materials

Upcycling of

[ Re-manu

Used wood

Used clay

34

Sanding

Slip ma

f materiality

Recreation in different function

ufacture ]

g down

Facade

aking

Facade

AD RC5&6 Clay Robotics | UCL 35

PROJECT BACKGROUND [CONCEPT]

Do we recognise how much materials we waste?

x3

The effects of construction activity on waste production are enormous. The industry produces 109m tonnes of construction waste each year (24% of total waste), of which up to 13% is delivered and unused. It produces three times more waste than all UK households combined. Although around half of this waste is reused or recycled, the amount that is simply disposed of remains alarming. ‘Construction and Sustainable Development’ Plain English, Constructing Excellence, Section 6, Page 1, 01/01/08

Than Total Waste of All UK households

109m Tonnes

Construction Waste

36

24%

Total Waste

what material we gonna do recycling?

200mm

300mm

(1.75 times exceeded for need) Wasted Clay Total Amount << Recycling

6400mm

3800mm Need Production Output

Tile Production Total Output Sep

Nov

Dec

Feb

[Clay Resources]

Jan

Feb

Mar

April

T:40mm

T:30mm

(x10)

(x22) [Wood Resources]

AD RC5&6 Clay Robotics | UCL 37

PROJECT BACKGROUND [SITE]

RIBA Introduction

BUILDING: ROYAL INSTITUTE OF BRITISH ARCHITECTS

38

PLAN : 1ST FLOOR OF RIBA

AD RC5&6 Clay Robotics | UCL 39

PROJECT BACKGROUND [SITE]

Site Analysis

section AAâ&#x20AC;&#x2122;

40

B

A

A’

B’

section BB’

AD RC5&6 Clay Robotics | UCL 41

42

AD RC5&6 Clay Robotics | UCL 43

44

WOOD STRUCTURE > Structure Design > Growth Distribution > Structure Installation

AD RC5&6 Clay Robotics | UCL 45

WOOD STRUCTURE [STRUCTURE DESIGN]

Structure Design Step1

Wood Unit

46

AD RC5&6 Clay Robotics | UCL 47

WOOD STRUCTURE [STRUCTURE DESIGN]

Structure Design Step2

Create a Surface to Control Wood Units

48

A Half-enclosed Shape to Cater for Visiting

AD RC5&6 Clay Robotics | UCL 49

WOOD STRUCTURE [STRUCTURE DESIGN]

Structure Design Step3

50

AD RC5&6 Clay Robotics | UCL 51

WOOD STRUCTURE [STRUCTURE DESIGN]

Structure Design Step4

Create a Wave Surface to Control Rising and Fall of the Top Area

52

A Wave Curve Would Make the Structure a Sense of Floating

AD RC5&6 Clay Robotics | UCL 53

WOOD STRUCTURE [STRUCTURE DESIGN]

Structure Design Step5

54

Some trees can be introduced in this system and make an artistic conception of a relationship between people and architecture and nature.

AD RC5&6 Clay Robotics | UCL 55

WOOD STRUCTURE [STRUCTURE DESIGN]

Structure Design Step6

56

For some parts, we adjust the density of wood structure (crossed part).

Furthermore, we add some wood bars to make the whole structure tensile.

AD RC5&6 Clay Robotics | UCL 57

WOOD STRUCTURE [GROWTH DISTRIBUTION] Structure Layers

58

LAYER 1

LAYER 2

LAYER 5

LAYER 6

LAYER 3

LAYER 7

LAYER 4

LAYER 8

AD RC5&6 Clay Robotics | UCL 59

WOOD STRUCTURE [GROWTH DISTRIBUTION] Component Installation

STAGE 1

60

STAGE 2

STAGE 3

STAGE 4

STAGE 5

AD RC5&6 Clay Robotics | UCL 61

WOOD STRUCTURE [STRUCTURE INSTALLATION] Structure Types

TYPE 2

TYPE 1

62

TYPE 5

TYPE 4

TYPE 3

AD RC5&6 Clay Robotics | UCL 63

WOOD STRUCTURE [STRUCTURE INSTALLATION] Structure Types

type 1 details

type 1 aggregation

64

type 1

type 2 details

type 2 aggregation

type 2

AD RC5&6 Clay Robotics | UCL 65

WOOD STRUCTURE [STRUCTURE INSTALLATION] Structure Types

type 3 details

type 3 aggregation

66

type 3

type 3 details

type 3 aggregation

type 3

AD RC5&6 Clay Robotics | UCL 67

WOOD STRUCTURE [STRUCTURE INSTALLATION] Structure Types

STEP 1

68

STEP 2

STEP

P3

STEP 4

STEP 5

AD RC5&6 Clay Robotics | UCL 69

WOOD STRUCTURE [STRUCTURE INSTALLATION] Final Structure

70

AD RC5&6 Clay Robotics | UCL 71

72

BATWING MINIMAL SURFACE > Minimal Surface Component > Component Assembling > Combination of Component and Structure

AD RC5&6 Clay Robotics | UCL 73

BATWING MINIMAL SURFACE [MINIMAL SURFACE COMPONENT] Generating Process

74

step1

ste step

step4

step

step7

ste step

ep2 p2

step3

p5

step6

ep8 p8

step9 AD RC5&6 Clay Robotics | UCL 75

BATWING MINIMAL SURFACE

step1

[MINIMAL SURFACE COMPONENT]

type 4

Component Study Minimal Surface

type 3

type 2

type 1

76

step2

step3

step4 overall geometry

AD RC5&6 Clay Robotics | UCL 77

BATWING MINIMAL SURFACE [MINIMAL SURFACE COMPONENT] Surface Stiffness

synclastic surface

anticlastic surface

1

2

3

4

5

6

7

8

9

10

11

generating process

78

12

elevation

first layer analysis

perspective

second layer analysis

AD RC5&6 Clay Robotics | UCL 79

BATWING MINIMAL SURFACE [MINIMAL SURFACE COMPONENT] Minimal Surface Save Material

bounding box

curvey geometry

short component: 0.212 m2 volume: 0.18 m3 area/volume ratio: 1.17 length: 300mm wideth: 300mm thickness: 150mm

long component: 0.34 m2 volume: 0.22 m3 area/volume ratio: 1.54 length: 300mm wideth: 600mm thickness: 100mm

80

0.18m3

0.22m3

0.08m3

minimal surface: 0.09 m2 volume: 0.08 m3 area/volume ratio: 1.125 length: 300mm wideth: 300mm thickness: 150mm

AD RC5&6 Clay Robotics | UCL 81

BATWING MINIMAL SURFACE [COMPONENT ASSEMBLING] Development of Mold

part 2

part 3

front view

82

back view

part 1

mold 2

mold 3

plan

elevation

perspective

mold 1

AD RC5&6 Clay Robotics | UCL 83

BATWING MINIMAL SURFACE [COMPONENT ASSEMBLING] Component and Structure

old mold only can print one type of component

new mold for printing

84

component

section AA

component

AD RC5&6 Clay Robotics | UCL 85

BATWING MINIMAL SURFACE [COMPONENT ASSEMBLING] Toolpath Development

type1

type4

86

type2

type3

type5

type6

AD RC5&6 Clay Robotics | UCL 87

BATWING MINIMAL SURFACE [COMPONENT ASSEMBLING] Universal Mold

empty

mold

m

mold

option

3

mold

88

option

4

mold op

tion 1

mold

mold op

option

2

tion 5

AD RC5&6 Clay Robotics | UCL 89

BATWING MINIMAL SURFACE [COMPONENT ASSEMBLING]

Different Types of Minimal Surface

type 1

type 1.1

type 2

type 2.1

type 3

90

type 4

type 4.1

type 4.2

type 5

type 5.1

type 5.2

type 5.3

type 5.4

type 5.5

type 6

type 6.1

type 6.2

type 6.3

type 6.4

type 6.5

type 7

type 7.1

type 7.2

type 7.3

type 7.4

type 7.5

type 8

type 8.1

type 8.2

type1

type2

type3

type4

type5

type6

type7

type8

AD RC5&6 Clay Robotics | UCL 91

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE] Gradually Varied Facade

92

AD RC5&6 Clay Robotics | UCL 93

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE] Varied Unit

94

AD RC5&6 Clay Robotics | UCL 95

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE] Varied Unit

96

AD RC5&6 AD Material RC5&6Consequences Clay Robotics | UCL 97

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE] Facade

98

AD RC5&6 Clay Robotics | UCL 99

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE] 3 Design Options

option1 4 components in 1 Box FRAME Hang on structure

option2 1 components in 1 Box FRAME Cupboard structure

option3 4 components in 1 Box FRAME Fitting structure

100

option 1 elevation

option 2 elevation

option 3 elevation

AD RC5&6 Clay Robotics | UCL 101

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE]

Option1 4 components in 1 Box FRAME

102

1000mm

500mm

420mm elevation

option 1

perpective

option 1 elevation

AD RC5&6 Clay Robotics | UCL 103

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE]

Option1 Hang on Structure

1 timber unit

axonometric with component

104

axonometric with component

section AA

section BB

AD RC5&6 Clay Robotics | UCL 105

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE]

Option2 1 components in 1 Box FRAME

106

1100mm

980mm

480mm elevation

option 2

perpective

option 2

perspective

AD RC5&6 Clay Robotics | UCL 107

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE]

Option2 Cupboard Structure

assemble 1 unit

108

1 unit

axonometric with component

AD RC5&6 Clay Robotics | UCL 109

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE]

Option3 4 components in 1 Box FRAME

110

1000mm

500mm

420mm

elevation

option 3

perpective

option 3

perpective

AD RC5&6 Clay Robotics | UCL 111

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE]

Option3 Fitting Structure

Fitting structure

Component assembling

112

1 unit

axonometric with component

AD RC5&6 Clay Robotics | UCL 113

BATWING MINIMAL SURFACE

[COMBINATION OF COMPONENT AND STRUCTURE]

Connection between Wood and Ceramic Pieces

114

axonometric with component NUT METAL RING WOOD BAR METAL RING RUBBER RING CERAMIC PIECE RUBBER RING BOLT

AD RC5&6 Clay Robotics | UCL 115

116

FABRICATION > Robotic Printing > Mold > Slip Casting > Firing > Installation

AD RC5&6 Clay Robotics | UCL 117

FABRICATION [Robotic Printing]

Form Finding by Robot Printing After the printing, we are waiting for 1 day, the will be nice surface. It will not crack. In order to take out of the component, we cut the one opening to make it easily.

In order to take out the clay component easily, we change the mold to plaster. Because plaster can absorbe the water in clay. But we have to take the clay within 1 day, otherwise the clay will crack.

118

top view of crack

top view of crack

top view of crack

top view of crack

AD RC5&6 Clay Robotics | UCL 119

FABRICATION [Mold]

CNC Mold and Plaster Mold

01

02

03

120

01 Making plaster by CNC mold to support printing.

02 Making negative mold by plaster.

03 Plaster mold

01

02

01 &02 Fixing the plaster mold 03 Key of Plaster Mold

03

AD RC5&6 Clay Robotics | UCL 121

FABRICATION [Slip Casting]

01

01& 02 Positive plaster mold and negative plaster mold.

02

122

03 Slip Casting

03

AD RC5&6 Clay Robotics | UCL 123

FABRICATION [Slip Casting]

124

AD RC5&6 Clay Robotics | UCL 125

FABRICATION [Slip Casting]

01

02

03

126

01 & 02 & 03 Slotting 04 &05 Joint half pieces by slip

04

05

AD RC5&6 Clay Robotics | UCL 127

FABRICATION

[Firing and Installation] Biscuit Firing

Glaze Firing

128

Installation

AD RC5&6 Clay Robotics | UCL 129

FABRICATION

130

AD RC5&6 Clay Robotics | UCL 131