BPro RC 5+6 2016/17_Composite [Skin] by SoomeenHahm Design

Composite [Skin] Research Cluster 5&6

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

COMPOSITE [SKIN] LIGHT WEIGHT COMPOSITE IN-FILL SYSTEM

Tutors: Daniel Widrig Guan Lee Soomeen Hahm Stefan Bassing Igor Pantic Adam Holloway TEAM MEMBERS: Thomas Bagnoli Evgenia Makroglou Kalliopi Mouzaki Darshan Singhania

[ INDEX ]

CHAPTER 1 | I N I T I A L S T U D I E S _ REFERENCES LATEX SKIN CHAPTER 2 | M A T E R I A L R E S E A R C H _

CHAPTER 7 | M I L A N D E S I G N W E E K _ CHAPTER 8 | D E V E L O P M E N T O F T H E S Y S T E M _ FABRICATION

TOOLS

DEVELOPMENT OF THE SYSTEM S U R FA C E B A S E D S T U D I E S

SOFT MEMBRANE FABRIC RESEARCH IN-FILL MATERIAL COATING AND FILLING TESTS MATERIAL KNOWLEDGE CHAPTER 3 | F O R M S T U D Y _ REFERENCES FIRST EXAMPLES FORM STUDY

FABRICATION STUDY I N T R O D U C I N G S T I T C H I N G PAT T E R N S

CHAPTER 4 | C O M P O N E N T S _ COMPONENT BASED MODELLING PHYSICAL MODEL D I G I TA L D E S I G N

PAT T E R N S T U D I E S FOLD STUDIES PIPE AND CONNECTIONS PHYSICAL FORM STUDIES D I G I TA L A G G R E G AT I O N S T U D I E S

CHAPTER 9 | B O U N D I N G F R A M E S T U D I E S _ SURFACE AGGREGATION STUDY

BOUNDING FRAME STUDIES

PIPE PINCHING STUDIES

B O U N D I N G F R A M E A G G R E G AT I O N

PHYSICAL STUDIES

D I G I TA L S P E C U L AT I O N

CHAPTER 10 | S T R U C T U R E C U R V E S T U D Y _ SURFACE AGGREGATION STUDY

FABRICATION STUDY

PIPES & CURVE BASED MODELLING PHYSICAL MODEL D I G I TA L D E S I G N

PHYSICAL HALF COLUMN CHAIR PROTOTYPE

L AT E X C O AT I N G

CHAPTER 5| P I P E S A N D C U R V E S _

D I G I TA L S T U DY

D I G I TA L S P E C U L AT I O N

CHAPTER 11 | A R C H I T E C T U R A L S P E C U L A T I O N _ SITE SELECTION DESIGN PROPOSAL

CHAPTER 6 | S U R F A C E S _ SURFACE BASED MODELLING PHYSICAL MODEL D I G I TA L D E S I G N

FABRICATION STUDY I N T R O D U C I N G S T I T C H I N G PAT T E R N S

ATTEMPT FOR AUTOMATION

AD RC5 & 6 Composite Skin | UCL - Bartlett

[ PROJECT INTRODUCTION ]

Inspired by the works of artists and architects that use hybridized material systems, our project revolves around a soft membrane composite for the production of innovative architectural elements of various scale, thus, more tactile spaces of unique spatial and visual impact. The research focuses on utilizing computational tools to research different design methodologies resulting to fabrication processes that employ material combinations which best represent the design intentions. It is an ongoing dialogue between material systems and digitally generated spatial forms. The project revolves around a flexible, soft material system; a composite that resembles skin that best complied with the free-form work that challenged us in our initial approach. More extensively, the core of the system is custom designed lycra components that are patterned and stitched choosing from a series of performavit patterns. These components are later filled with Polystyrene Beads that are controlled and constrained respectively. The final steps evolve coating the resulted product with a unique

material that gives a rubber-based, glossy appeal to the folded and stitched surfaces, that is, clear liquid latex. Applying the latex provides lightweight, semi-rigid, self-bearing components with a resistance to compression. Being able to sustain formation and withstand neighbouring surface arrangements, bigger aggregations are achieved. Using conventional materials such as lycra and latex as form work manipulated in unconventional ways employing techniques such as stitches pinches and folds allowed us to grow in scale in a very efficient, fast, inexpensive way. The physical properties of the system could be exploited in creations of waterproof, insulating, spaces. However, the outward appearance could have a much more striking visual impact as it unorthodoxy combines a strong bond with the human body as well as an unearthly grotesque, bulbous physical phenotype that all together evokes an unusual, multisensory, twisted experience. A spatial experience that is contradicting minimal modern styles with a maximalist richness of form.

AD RC5 & 6 Composite Skin | UCL - Bartlett

CHAPTER |1 INITIAL STUDIES

REFERENCES LATEX SKIN

[ COMPONENTS ] AD RC5 & 6 Composite Skin | UCL - Bartlett 11

[ REFERENCES ] INSPIRATION

LATEX

[ BART HESS, “MUTANTS” ]

The reaction of latex with the human body. Textural effects, material expression techniques.

[ Initial Research | References ]

[ BART HESS, “THE GROTTO” ]

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[ INITIAL STUDIES] LATEX SKIN

SKIN AND MEMBRANE

Soft skin membrane structure which could express materiality through textural expression.

[ Initial Research | Latex Skin ]

LIQUID LATEX

These initial ideas were experimented and realised through a â&#x20AC;&#x2DC;cyber wearableâ&#x20AC;&#x2122; achieved with liquid latex on stretched latex sheets. Limitations with the sheet to combine with each other and its ability to stretch and stay in desired shape. AD RC5 & 6 Composite Skin | UCL - Bartlett 15

CHAPTER |2 MATERIAL RESEARCH

REFERENCE PROJECT HIGHLIGHT SOFT MEMBRANE & GRANULAR MATERIAL COMBINATION FABRIC RESEARCH I N - F I L L M AT E R I A L- CO AT I N G A N D F I L L I N G T E ST MATERIAL KNOWLEDGE

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[ REFERENCES ]

Effects of texture, blobs, skin and body like features.

1 2 4 3 5 1. Anastasia Pottinger 2. Louise Bourgeois 3. Jason Hopkins,Abhnominal 4. Jenny Saville,Closed Contact 5. Rosa Verloop

7 8 6 9 10 11 6. Chemin De Chair 7. Rosa Verloop 8. Rosa Verloop 9. Jolanda van Meringen 10. Georgina Santiago 11.Frederic Fontenoy

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[ REFERENCES ]

[ PINFILL, THE BARTLETT, AD RC6 ]

Material control with pinching and folding . Its effect on the texture and form.

[ MATSYS, DIFFERENT PROJECTS ]

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[ PROJECT HIGHLIGHT ] DESIGN DEVELOPMENT LOGIC

The digital research focuses on three strategies for growth through aggregation. These aggregation logic are planned in order to have a systematic approach which can guide the fabrication process simultaneously. Overall, each process has a surface with its own pattern some with unique shape forms and also variations in pattern density and style. These surfaces are self pinched and folded before they are connected with each other using one of the three aggregation logics.

CO LU M N A N

WA L L

CO LUM N

PAVI L I O N

C AN OPY

CO M P O NE NT AG G R EG AT I O N O N ST R U C T U R E

N D C E ILIN G

BO U ND I NG F R AME AG G R EG AT I O N

PIPE COMPON E N T CON N EC T ION

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[ MATERIAL RESEARCH ] SOFT MEMBRANE & GRANULAR MATERIAL COMBINATION

G R A N U LA R

RIGID

A BR

T he go al is to ac hieve a lig ht we ig ht composite compo nent wh ich has t he abilit y to c re ate volume and fo rm . T his w ill e nable us to mate rialize rigorous organic co m po sit ions t hat reflet our de sig n v ision. L AT E X

At t he en d dig ital de sig n and fabricate will coope rate harm o niously. O n t his note , t he aim is to se le c t a lig ht weig ht g ranular infill mate rial whic h has possibilit ies to ac hieve a form, at t he same t ime re ac t well wit h fab ric and harde n t he composit ion wit h a t hird ing red i e nt , liquid L AT E X .

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[ MATERIAL RESEARCH ] FABRIC RESEARCH

STRETCH TEST

Fi rst we a re testing the sof t membra ne we a re going to wor k with. T he go a l i s to se l e ct a fabr ic with maxim um stretc h a bility, there by, a fabr ic t hat wi l l a l l ow to achieve tension and r i g i di ty.

VISCOSE

LYCRA

20 cm x 20 cm

0.0

0.5

Stretching percentage :

0.0

0.5

Stretching percentage : 20 % stretch

20 cm x 20 cm

40 % stretch

NYLON

NYLON SOCK

20 cm x 20 cm

0.0

0.5

Stretching percentage :

0.0

0.5

Stretching percentage : 60 % stretch

Nylon 94 % Lycra 6 % :

80 % stretch

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[ MATERIAL RESEARCH ] IN-FILL MATERIAL

IN-FILL TEST

Probably the most important part of the project is to select a granular material that could serve as the mass of a physical prototype filling the soft membrane. The criteria for choosing would be weight, density, price, availability, physical properties and the probability of it to be coated and hence bonded in a solid, stable, rigid manner that could provide mechanical properties.

HARD

WEIGHT

RICE

SAW DUST

HEAVY

LIGHT

LIGHT POLY PELLETS SOFT

PHYSICAL PROPERTIES

VOLUME OCCUPIED 1 Kg

Density

High

Low

1 Kg

High

Saw as an infill makes a light weight prototype with a low density and a medium volume. Ideal for a prototype but has tendency to absorb water which makes its bulky and heavy.

High

Poly-pellets as an infill makes a medium weight prototype with a medium density and a low volume. Its fire retardant. Limited with size various in poly-pellets.

Density

Low

1 litre

Density

Low

Rice as an infill makes a heavy weight prototype with a high density and a low volume. Making the prototype even more heavier while trying to achieve large pieces. Stability is good as it heavy and the rice stays in place.

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[ MATERIAL RESEARCH ] IN-FILL MATERIAL

IN-FILL TEST

HARD

WEIGHT

POLYSTYRENE BEADS

POLYSTYRENE FIBERS

EXTREMELY LIGHT

HEAVY FLOUR SOFT

PHYSICAL PROPERTIES

VOLUME OCCUPIED 1 litre

Density

High

Low

Polystyrene Balls as an infill makes an extremely light weight prototype with a low density and a high volume. Also has good compression with balls of bigger diameter allowing structural possibilities.

1 Kg

Density

High

Low

1 Kg

Density

Low

High

Polystyrene Fibre as an infill makes an extremely light weight prototype with a very low density and a high volume. Possibility to form shapes and forms. Absorbs liquids which reduces the volume and increases the density.

Dough as an infill makes a heavy weight prototype with a high density and a low volume. Possibility to form shapes and forms. Takes a long duration to dry completely drying it to harden.

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[ MATERIAL RESEARCH ] COATING AND FILLING TESTS

POURING

INFERENCE

The process involves mixing the selected INFILL material (POLYSTYRENE BEAD - 2 mm to 5 mm) with adhesives, then filling the above in the fabric medium. Deforming it to desired shape and leaving it alone to dry.

In first three tests it makes it difficult to fill more quantity of adhesive and polystyrene beads. Material do not allow to control form. Flour and water makes dry dough which hardens to desired form. Very heavy once completely dry.

Test 1: Polystyrene glue + Polystyrene Beads + Fabric

Test 2: PVA + Polystyrene Beads + Fabric

Test 3: Liquid Latex+ Polystyrene Beads + Fabric

Test 4: Flour + Fabric

COATING

The process involves coating the base sample prototype (POLYSTYRENE BEAD- 2 mm to 5 mm + Nylon fabric), with different liquid based mixtures. The shape/form is achieved before coating and left to dry.

Weight:

After

Number of coats: Drying time:

Thick coat > 8 Hours

Plus curing

After

Number of coats:

Thick coat

Drying time:

> 5 Hours

Rigidity/stiffness:

Rigidity/stiffness: Inference:

Weight:

Coating with a mixture of cement and sand changes the physical appearance and texture of the fabric.

Inference:

Coating with a layer of plaster changes the physical appearance of the fabric. Cracks are developed when hammered

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[ MATERIAL RESEARCH ] COATING AND FILLING TESTS

POURING

Before coating After

Weight:

Thick coat

Number of coats: Drying time:

> 1 Hour

After each drying

Number of coats: Drying time:

2-3 Hours

Rigidity/stiffness:

Rigidity/stiffness: Inference:

After coating

Weight:

Coating with a layer of silicone changes the physical appearance of the fabric. Very difficult to control.

Inference: Coating with two layers of Latex. Allows visual transparency and adds friction. Water proof properties.

FINAL FABRICATION MATERIALS

TARGET

In our case polystyrene bead measuring 2 mm to 5 mm are used as an infill and polystyrene balls measuring 30 mm to 120 mm are used a form expresser. The combination of these two with the soft membrane (fabric) is used to carry out tests to achieve a rigid steady composite. The model is later dipped in latex to finish the process achieving a rigid composite component which has friction and is coated in a water-proof way.

WEIGHT

Light Weight composite

APPEARANCE POLYSTYRENE BEADS

Rubbery transparent glossy finish

FORM LYCRA

LIQUID LATEX

Ability to create form with sticks, pins and constrains

RIGIDITY

Rigid form with friction and compression strength

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[ MATERIAL RESEARCH ] MATERIAL KNOWLEDGE

THE HARVEST OF RUBBER

The rubber trees produce latex all year round, but rubber tappers normally produce most rubber between the dry season months of April and September.

Latex is a product of rubber tappering. Workers expertly cut multiple gashes in rubber trees to collect the white sadestined for the nearby factory.

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[ MATERIAL RESEARCH ] MATERIAL KNOWLEDGE

Polystyrene is a synthetic polymer made from the monomer styrene. Polystyrene can be solid or foamed. General-purpose polystyrene is clear, hard, and rather brittle. It is an inexpensive resin per unit weight Waste EPS have been crushed into pieces and beads, and the crushed EPS beads can be made into other products . Polystyrene Beads 3 mm - 5 mm. Polystyrene Balls 30 mm - 120 mm.

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[ MATERIAL RESEARCH ] MATERIAL KNOWLEDGE

MATERIALS & APPLICATION

[ LIQUID LATEX ]

Sport- Swim Caps Medicine- Catheters Industrial - Mattresses Fashion - Clothing Apparels Industrial - Surgical Gloves Industrial - Condoms Industrial - Latex Paints

[ STYROFOAM ]

Craft- For Decoration Others- Cups, glasses , plate Art - Sculptural installation Construction - Insulations Interior- Bean Bags Others - General Insulation Art- As a Mold

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CHAPTER |3 FORM STUDY

FIRST EXAMPLES FORM STUDY FABRICATION STUDY I N T R O D U C I N G ST I TC H I N G PAT T E R N S

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[ FORM STUDY ] INITIAL STUDIES

FORM-FINDING

Some of the first experiments involved further material exploration. Every material combination brings variations to be studied and each system demands different manipulation methods to take the form that best suits its particularities.

MATERIAL COMBINATIONS 1. Polly Pellets+Rubber bands+Latex 1. Cork+ Fabric+Latex 2. Rice+Rope+Fabric 3. Foam boards+Fabric 4. Beads+Rubber bands+Latex 5. Fabric+Sticks+Beads 6. Cotton wool+Stitches+Fabric

1 2 3

By variating the methods of tying the fabric and the ways to restrain the in-fill material , a catalogue of forms is produced. Some of the ways included extensive stitches or topical pinning, knotting with rubber bands and rope or cable ties.

4 5 6

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[ FORM STUDY ] INITIAL STUDIES

INFERENCE

First experimentations with several different material systems led into a large production of grotesque looking small compositions. With criteria such us the ability of making an impact, having an appeal but most importantly having the potential to be controlled and harnessed we decide to choose qualities from each example we create and assess them into future experimentations.

MATERIAL COMBINATIONS 1.Polysterene Balls+Beads+Fabric+Latex

METHOD

-SPHERES IN USE

Since Styrofoam beads are a granular material so light and soft that cannot represent the rigidness in the system we add Styrofoam balls of various sizes that are capable of holding enough pressure so that our system is considered rigid.

3.0 cm 6.0 cm

9.0 cm

12.0 cm

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[ FABRICATION STUDY ] I N T R O D U C I N G ST I TC H I N G PAT T E R N S

STITCHING BY HAND

Stitching the fabric is an efficient way of pulling the material into a state of semi-regidness. In combination with the polysterene balls of different sizes, stitches introduce another layer in the design process. Initially the stitches were made by hand and the pattern was decided according to the movement and best manipulation of the in-fill granular material.

1.Linear half cross stitching 2.3.4.Local half cross pinning

1 2 3 4

Half cross pin

Full cross pin:

_PROCESS OF PINNING

PINNING PATTERNS

Half cross pinning pattern is the simplest in terms of difficulty and cleaner in terms of outcome.

Full cross pinning pattern is more time consuming but the result is a stronger pin that can hold the tension of the fabric.

Linear half cross stitch:

Linear full cross stitch:

_PROCESS OF STITCHING

STITCHING PATTERNS

Linear half cross stitching pattern is the simplest. It involves the risk of ripping the fabric due to high tension.

Linear full cross stitching pattern is more time consuming. It secures the stitches and eliminates the risk of ripping the fabric.

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[ FABRICATION STUDY ] I N T R O D U C I N G ST I TC H I N G PAT T E R N S

STITCHING BY HAND

1.2.3.4. Stages of pinning.

Stitching by hand is a long process that is to be enhanced parallel to the overall fabrication melioration. So far the need for refinement was noted. Some of the causes of the general rough quality of the stitches and pins are thought to be the tension of the baric, the difficulty in retaining a form working the light weight beads that flow in the interior and the balls that are being positioned on the edges.

Tension

After Pinning

< After Pinning

The graph shows how different patterns can generate variations in the formation of the beads and how tension plays a significant role in the system not only for rigidity but also form wise.

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CHAPTER |4 COMPONENTS

The approach of using points as nodes and lines as their bridges are used as basic form generators. Stitches and pins that hold spheres in place add textural appearance to each prototype. These prototypes-components in combination with each other help create various compositions. Also different techniques are explored to create better interlocking circumstances.

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[ COMPONENT BASED MODELLING ] PHYSICAL MODEL

COMPONENT MAKING

The connection of spheres with sticks was a solution to address the issue of interstitial softness. sticks was a way to control the direction of the stocks and the twist of the geometry.

Step 1

Step 2

Step 3

Step 4

Step 5

Process | System

Fabric

Polystyrene Beads

Latex coating

Process | Aggregation

[ DETAILS ]

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[ COMPONENT BASED MODELLING ] PHYSICAL MODEL

COMPONENT MAKING

Friction from the latex and volume from the polystyrene spheres as well as curves generated by the stretched fabric allowed the possibility of having interlocking components that could intertwine or weave.

Step 1

Step 2

Step 3

Step 4

Step 5

Process | System

Fabric

Polystyrene Beads

Latex coating

Process | Weaving

[ INTERLOCKING ]

[ SURFACE ]

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[COMPONENT BASED MODELLING ] PHYSICAL MODEL

COMPONENT MAKING

By simplifying the process of component making we end up with V-shaped components which have the ability to interlock and pile with other similar to build a bigger in scale model.

Step 1 | Sphere Location

Fabric

Step 2 | Fabric

Polystyrene Beads

Step 3 | Stitch profile

Latex coating

Process | Piling up

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[ COMPONENT BASED MODELLING ] DIGITAL STUDY

PROCESS

V-shape components figured in formations and aggregated give compositions of limitless possibilities for further digital speculation.

Component | Generation

[ POINTS AND LINES ]

[ BRIDGE CONNECTION ]

[ BASIC COMPONENTS ]

[ VARIATION OF SPHERE SIZES ]

component 1 60

component 2

component 3

Component | Interlocking

component 1

component 2

component 3

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[ COMPONENT BASED MODELLING ] DIGITAL STUDY

PROCESS

V-shape components inflated and given volume generate more intense curves and consequently better interlocking possibilities.

Component | Multiplication

Rotate and place

component 1

Growth by addition

component 2

Growth by aggregation

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[ COMPONENT BASED MODELLING ] DIGITAL STUDY

OUTPUT

component 3

Growth by aggregation

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[ COMPONENT BASED MODELLING ] DIGITAL STUDY

PROCESS

Spheres play a significant role on our design process hence they control the methodology of the connectivity of components. Different sphere sizes are distinguished in this specific design and families of concentrations exist in areas of were joints are obvious.

[ POINTS ]

[ BRIDGE CONNECTION ]

Growth

Component | Aggregation

Component 1

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[ COMPONENT BASED MODELLING ] DIGITAL STUDY

OUTPUT

top view

left view

right view

front view

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[ COMPONENT BASED MODELLING ] DIGITAL STUDY

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[ COMPONENT BASED MODELLING ] PHYSICAL MODEL

COMPONENT MAKING

Aiming for larger scale than the one achieved we fabricated a weaving system that grow s allowing the addition of more components by the method of interlocking into its vacant cavities.

Step 1

Step 2

Step 3

Step 4

Process | System

Fabric

Polystyrene Beads

Latex coating

Process | Weaving

[ CURVES ]

[ INTERLOCKING ]

[ BASE STRUCTURE ]

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[ COMPONENT BASED MODELLING ] PHYSICAL MODEL

WEAVING COMPONENTS

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[ COMPONENT BASED MODELLING ] DIGITAL DESIGN

PROCESS

Referring to the previous design work this design catalogue adds more control to the relationship of linear parts and spheres. Spheres represent points of rotation and the whole component resembles human “bones”.

Component | Assembly

[ POINTS ]

[ LINES ]

Front

Side

composition | connections

Component | 1

Component | 2

Component | 3

composition | perspective

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[ FABRICATION STUDY ] LATEX COATING

LATEX-COATING COMPONENTS

2 3 1

1.2. Pouring liquid latex 3.Hanging and draining

After the physical model is totally stitched and fixed into position the coating process can begin. Safety pins are holding the model into stability from a wooden frame in a vertical manner so they can be exposed into air from all sides. in that way the liquid latex dries faster. It takes approximately 12 hours (always according to size) for the Latex to be absorbed.

LATEX-COATING COMPONENTS

1 2

1.2.Matured latex changes color, it Darkens.

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[ FABRICATION STUDY ] LATEX COATING

Fabric Thickness | Adhesive penetration Research

Dipping time: 15-20 minutes [ TEST 1: NYLON 94% LYCRA 6% SOCKS/ TIGHTS ]15 DENIER ]

[ TEXTURE ]

[ LATEX PENETRATION ]

[ SOCK ]

Fabric Toughness & Stitching

Fabric Colour Gradation with beads

Shape deformation after Latex : Fabric Customizing

High deformation :

Does not allow fabric customizing. Also limits stitch patterns. Does not allow possibility of surface formation.

Rips stitches easily

Dipping time: 15-20 minutes [ TEST 2: LYCRA TWO WAY STRETCH-60WID ]

Fabric Toughness & Stitching

Fabric Colour Gradation with beads

Shape deformation after Latex : Fabric Customizing

[ TEXTURE ]

[ LATEX PENETRATION ]

High deformation :

Does not allow fabric customizing. Also limits stitch patterns. Does not allow possibility of surface formation.

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[ FABRICATION STUDY ] LATEX COATING

Fabric Thickness | Adhesive penetration Research

Dipping time: 15-20 minutes [ TEXTURE ]

[ TEST 3: LYCRA TWO WAY STRETCH ]

Fabric Toughness & Stitching

Fabric Colour Gradation with beads

Shape deformation after Latex : Fabric Customizing

High deformation :

Does not allow fabric customizing. Also limits stitch patterns. Does not allow possibility of surface formation.

[ LATEX PENETRATION ]

Dipping time: 15-20 minutes [ TEST 4: 100 DENIER ]

[ TEXTURE ]

[ LATEX PENETRATION ]

[ SOCK ]

Fabric Toughness & Stitching

Fabric Colour Gradation with beads

Shape deformation after Latex : Fabric Customizing

Gradation from black to white when stretched Low deformation

Does not allow fabric customizing. Also limits stitch patterns. Does not allow possibility of surface formation.

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[ FABRICATION STUDY ] LATEX COATING

CURING WITH SPESIALIZED PRODUCTS

1.Recently coated 2.Months after coating

The glossy finish attracts dust and so depending on the circumstances of its exposure, the models can easily change colorations and texture. With the proper treatment it can retain its original state.

PRESERVING GLOSSINESS

1.2. Cleaning dust 3. Spraying to retain glossiness

With the proper treatment, specialized in preserving latex capabilities the physical model can retain its original appearance and state.

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CHAPTER |5 PIPES & CURVES

On this chapter we use pipes/curves as a basic form generator along with stitches and pins that control bent and add textural appearance to each prototype. These prototypes in combination with each other create a weaving composition. The advantage of this over the component approach would be the ability of each prototype to be flexible without a supporting under structure (sticks).

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[ PIPES & CURVE BASED MODELLING

]

DIGITAL DESIGN

PROCESS

Component | Curves & Weaving

[ CURVES ]

Twisting

[ SPHERES ]

Growth

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[ PIPES & CURVE BASED MODELLING

]

DIGITAL DESIGN

OUTPUT

top view

bottom view

left view

back view

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[ PIPES & CURVE BASED MODELLING

]

DIGITAL DESIGN

PROCESS

This design example combines component based logic with independent line-work. Lines are being translated into curved weaving branches that act as a tractors to interlocking families of spheres. These families concentrate on focal points of the design.

Component | Curves & Weaving

[ CURVES ]

Weaving Combining

Deforming

Twisting

Component | Interlocking Spheres

[ SPHERES ]

Component 1

Component 2

Component 3

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[ PIPES & CURVE BASED MODELLING DIGITAL DESIGN

Component | Curves & Weaving

]

Component | Interlocking Spheres

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[ PIPES & CURVE BASED MODELLING DIGITAL DESIGN

OUTPUT

]

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[ PIPES & CURVE BASED MODELLING

]

DIGITAL DESIGN

PROCESS

In the demonstrated design work we experiment with giving curves the first role. Spheres take position on the edges as handles for each curve. Later on, pipes intertwine.

Component | Curves & Weaving

Component | Interlocking Spheres

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[ PIPES & CURVE BASED MODELLING

]

DIGITAL DESIGN

OUTPUT

bottom view

100

front view

combination

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[ PIPES & CURVE BASED MODELLING ] PHYSICAL MODEL

102

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[ PIPES & CURVE BASED MODELLING ] PHYSICAL MODEL

PROCESS

On this example we further explore the connection between the components. We create models that have a whole in which one can add a “pipe” shaped piece and scale up.

Process | Elements

104

Fabric

Polystyrene Beads

Latex coating

[ TYPOLOGY_1 ]

Fabric

Polystyrene Beads

Latex coating

[ TYPOLOGY_2 ]

Process | Interlocking & Weaving

Process | Aggregation

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[ PIPES & CURVE BASED MODELLING ] DIGITAL DESIGN

REALIZING THE PHYSICAL MODEL

Modelling | Sculpting

[ PRTOTOTYPE_1 ]

106

[ PRTOTOTYPE_2 ]

[ VOID ]

[ INTERLOCKING ]

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[ PIPES & CURVE BASED MODELLING ] DIGITAL DESIGN

REALIZING THE PHYSICAL MODEL

Modelling | Sculpting

[ POINTS ][ CURVES ]

Growth

108

[ INTERLOCKING ]

[ VOID ]

[ SURFACE ]

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[ PIPES & CURVE BASED MODELLING ] PHYSICAL MODEL

SYMMETRY & SURFACE DEMONSTRATION

This specific composition illustrates how connection pieces with wholes are designed on a composition that also shows symmetry. Also surface based MODELLING is being introduced in the process.

Process | Elements

Step 1

Fabric

110

Step 2

Step 3

Polystyrene Beads

Step 4

Latex coating

Process | Interlocking & Weaving

Process | Aggregation

[ SURFACE ]

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[ PIPES & CURVE BASED MODELLING ] PHYSICAL MODEL

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[ PIPES & CURVE BASED MODELLING ] DIGITAL DESIGN

REALIZING THE PHYSICAL MODEL

Modelling | Sculpting

[ POINTS ][ CURVES ]

Growth

114

[ INTERLOCKING ]

[ SURFACE ]

[ VOID ]

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CURVES

The curve based approach was rejected and moved over to a surface based approach. As the later was not giving enough material to achieve stiff components. As the base material is light the density was too less making the curves less stable.

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SURFACES

The advantage of the surface over the curves was increased volume and density of the infill making the prototypes more stable and easy to control.

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CHAPTER |6 SURFACES

In this approach, surfaces are used as basic form generator. Starting from the generation of a 2d pattern on a flat surface, we create the paths that help this surface to bend and fold in different ways and create different shapes and forms.

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[ SURFACE BASED MODELLING ] PHYSICAL MODEL

The whole approach is divided in 3 stages. As a first step, we approached the surfaces as separate pieces that can be folded in different ways. Subsequently, in order to achieve aggregations of these pieces, we divided the surfaces in 2 sub elements. Surfaces that have holes and surfaces that have elongated pipes which can fit in the surfaces and interlock with them.

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SURFACES WITH HOLES SURFACES

SURFACES AND PIPES

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[ SURFACE BASED MODELLING ] PHYSICAL MODEL

PATTERN STUDY

Different patterns of stitching on surfaces were explored. Through this process, we have studied a variation of different folding techniques based on the different patterns and pins that would give to our piece a different form each time.

Process | Stitching > Folding > Pining

Direction| Horizontal

Variations| Symmetry

124

Direction| Curve

Spacings| Pipes

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[ SURFACE FOLDS]

Extracting the outline points of the surface we have explored some combinations of joining those points so that they could simulate the folding process. In these 2 examples, we are examining the simplest combinations of joining the main points- top bottom and middle ones.

Physical| Front

126

Step 1| Front

Step 2| Back

Physical| Front

Step 1| Front

Step 2| Back

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[ SURFACE FOLDS]

In these examples, we are examining more complex combinations, where the points join also after being folded.

Physical| Front

128

Physical| Side

Step 1| Front

Step 2| Back

Physical| Front

Physical| Back

Step 1| Front

Step 2| Back

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[ SURFACE FOLDS]

In these examples, ONE surface is folded in 8 different pinning/ folding strategies. Each of these has its own unique configuration in spite of having the same stitching pattern.

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[ COLUMN SPECULATION ]

The idea to use one of the above configurations in a vertical composition resembling an imitation of a gothic column. The below piece is achieved by using 3 of the many configurations.

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[ DIGITAL MODELLING]

The use of generative system to simulate pins and folds to resemble the physical prototypes. The process involves surface MODELLING using inflation compression through point pinning.

[ SURFACE ]

[ LYCRA SHEET / SURFACE ]

[ STITCH PATTERN ]

[ FOLDING POINTS ]

[ PINCH POINTS ]

136

Front

Back

Side

[ FOLDS/PINCHES ]

[ INFLATION]

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[ DIGITAL MODELLING]

Using the above pinning techniques to replicate the physical configurations in the digital medium. Speculations of architectural applications like columns through vertical aggregations.

Back 138

Side

Front

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[ DIGITAL MODELLING]

Using the above pinning techniques to replicate the physical configurations in the digital medium. Speculations of architectural applications like columns through vertical and horizontal aggregations.

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CHAPTER |7 MILAN DESIGN WEEK 2017 A seven day intense workshop in Milan conducted during Milan Design week 2017

Installation for the Sense Me SBODIO 32 space. Themed around the idea of bodily texture and forms, the installation attempted to create a spacial composition which the visitors could walk around and sense through touch and fell. The fabrication also proposed a wearable which the visitors could wear over themselves experiencing to be one with the surrounding composition. AD RC5 & 6 Composite Skin | UCL - Bartlett 149

[ MILAN DESIGN WEEK]

Digital Research Exploration

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[ Milan Design Week ] Large scale Aggregations

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[ Milan Design Week ] Large scale Aggregations

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CHAPTER |8 DEVELOPMENT OF THE SYSTEM

FABRICATION TOOLS DEVELOPMENT OF THE SYSTEM SURFACE BASED STUDIES PAT T E R N ST U D I E S FOLD STUDIES PIPE AND CONNECTIONS PHYSICAL FORM STUDIES DIGITAL AGGREGATION STUDIES

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[ FABRICATION ] FABRICATION TOOLS

Lycra

Fabric tracing paper

From 2d stitch pattern

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Sewing Machine

Polystyrene Beads

Vinyl pipe

Liquid Latex

Pnevac gun

Gravity spray gun

compressed air pump

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[ FABRICATION STUDY ] ATTEMPT TOWARDS AUTOMATION

USING PNEVAC AIR PUMP GUN

Manual filling system

Mechanical filling system

from bead bag

to fabric surface from compressed air pump

Meat Grinder

PnueVac Air Gun Pump > 6 Hours

30min - 1 Hour

Time duration :

Handling

extremely difficult

Very fast and easy to handle

with lots of beads wastage(> 20%)

with less beads wastage (<5%)

The first attempt was the use of meat grinders, this was better than the earlier approach but however did not prove to be fast, also there is loss of beads in process of filling. The second attempt (PneVac Air pump Gun system) proved much better in terms of time saving strategies and also helped in achieving lesser than 5% of polystyrene beads loss during infill process.

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The assembly of the Pnevac Air pump system is done as shown in the 2d drawings. The Long tube is used to reach the other end of the pre stitched fabric sheets and pump to let the beads fill the space between the stitches to its maximum capacity. Care is taken to make sure even quantity of beads are pump into the surface.

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[ FABRICATION STUDY ] ATTEMPT TOWARDS AUTOMATION

USING GRAVITY SPRAY GUN

Manual - Pouring

Mechanical- Spraying system

liquid latex (600 ml)

from compressed air pump > 3 Hours

30min - 1 Hour

Time duration :

Handling

Time consuming and extremely difficult to handle

Very fast and easy to handle

The first attempt was to pour or dip the prototypes in a tub of latex. This approach did have a lot of limitations with the scale of the prototype and also with the finish of the dipped prototype as it ends up being messy and does not have a uniform coating. The second attempt makes use of a conventional gravity spray gun which helps in spraying a neat and clean coat of liquid latex. It also is easy to handle and quicker than the old process. This step towards a more mechanical approach helps in also saving the amount of liquid latex sprayed. 162

The assembly of the Gravity air gun is done as shown in the 2d drawings. A compressed air supply is needed to complete the set up. The nozzles are adjusted to achieve optimum spray quality and speed. The spray gun is also maintained with a liquid thinner to prevent the latex from drying inside the gun.

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[ DEVELOPMENT OF THE SYSTEM ] The fabrication system was developed further to make better possibilities for connection leading to aggregation. In order to achieve this, use of vinyl pipes are used along with the edges of the surface. This pipe now holds possibilities for component connections.

Single Surface

164

5 component

t connection

Vinyl pipe Semi Rigid flexible pipe to control edge and connect with neighbour component Connection

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[ SURFACE BASED STUDY ] ST I TC H PAT T E R N ST U DY

DIFFERENT PATTERN EFFECTS FOR SAME FOLD

2d pattern 166

physical samples

2d pattern

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[ SURFACE BASED STUDY ] ST I TC H PAT T E R N ST U DY

DIFFERENT PATTERN EFFECTS FOR SAME FOLD

The same is explored in the digital world to see how close the results are to the physical prototypes.

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[ SURFACE BASED STUDY ] FOLDING AND PINNING VARIATION

FOLD STUD - PATTERN VARIATION

The ability of the same surface folding and pinching in different permutations and combinations gives multiple prototypes. Each reflecting the same pattern in a different way because of simple changes in folding strategy.

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[ SURFACE BASED STUDY ] PHYSICAL MODEL

SHAPE STUDY

The newly introduced pipes are now tested with different shapes of surfaces. Each of these shapes are tested for flexibility in component aggregation possibilities. Its possibility to increase in scale and adopt various stitch patterns.

The rectangle being the shape from early studies was the first surface to adopt this new connection system. However through study , the need for a more closed loop for the pipe to go all around was needed.

Bean shaped components. This shape has a natural geometric allowing possibilities of nesting with each other. Giving possibilities for connections.

The ellipse proved to be the most efficient shape as it gives way for multiple connection possibility.

The ellipse shape is then developed further to have possibilities of surface penetrating through it self.

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INTRODUCING PIPES

> Control over Bends and Folds > Possibility of connections

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[ PHYSICAL FORM STUDY ] COMPONENT RESEARCH _ RECTANGLE

FOLD STUDY FOR AGGREGATION

The rectangular surface with its pipes along the edges is folded in several ways. From a simple fold forming a cylinder to more complex and intricate folds.

Pinching and connection joint

174

Selected Folded profiles Views

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[ PHYSICAL FORM STUDY ] COMPONENT RESEARCH _ RECTANGLE

FOLD STUDY FOR AGGREGATION

The interesting folded components are replicated and tested for the possibilities of aggregation through connections.

Connection joint

176

Two component assembly

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[ PHYSICAL FORM STUDY ] COMPONENT RESEARCH _ ELLIPSE

FOLD STUDY FOR AGGREGATION

With limitations with the rectangular shape, the research adopts the same approach with an elliptical shape. Aggregation with three ellipse shaped surface >surface fold and connection exploration >aggregation along curve

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[ PHYSICAL FORM STUDY ] COMPONENT RESEARCH _ ELLIPSE

FOLD STUDY FOR AGGREGATION

Aggregation with three ellipse shaped surface >surface fold and connection exploration >aggregation along curve

FLAT

180

SINGLE FOLDED SURFACE

Aggregated components

PHYSICAL AND DIGITAL MODELLING

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[ PHYSICAL FORM STUDY ] COMPONENT RESEARCH _ ELLIPSE

FOLD STUDY FOR AGGREGATION

Aggregation with two ellipse shaped surface >surface fold and connection exploration >aggregation along curve

Folding (pining) : Stacking

Connection + Folding (pining)

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Folding (pining) + connection

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[ PHYSICAL FORM STUDY ] COMPONENT RESEARCH _ BEAN

FOLD STUDY FOR AGGREGATION

Aggregation with two bean shaped surface >surface fold and connection exploration >aggregation along curve

Bean 1

Two connected beans: One component

Bean 2

Folding and Pinching

Connection Point

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[ PHYSICAL FORM STUDY ] COMPONENT RESEARCH _ BEAN

MULTIPLE COMPONENT AGGREGATION

2 bean components

3 ellipse components

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2 ellipse with hole components

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[ DIGITAL AGGREGATION STUDY ] COMPONENT RESEARCH_CATALOGUE

FOLD STUDY FOR AGGREGATION

The study involves modelling surfaces with different fold and pinches. A catalogue of folded surface is then used to create a composition through aggregation and connecting pipes of its respective neighbouring component. An attempt to model a mega component is also achieved which has the ability to connect to more than one neighbouring component.

1 Pinch

2 Pinch

MEGA COMPONENTS 188

4 Pinch

2 SINGLE COMPONENT AGGREGATIONS CONNECTION

1 SINGLE COMPONENT AND 1 MEGA COMPONENT AGGREGATION

1 SINGLE COMPONENT AND 2 MEGA COMPONENT AGGREGATION

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[ DIGITAL AGGREGATION STUDY ] COLUMN AND WALL STUDIES

SINGLE COMPONENT AGGREGATION AND CONNECTION

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[ DIGITAL AGGREGATION STUDY ] AGGREGATION_SPECULATION

CANOPY AGGREGATION

The developed catalogue and the connecting logic is used to aggregate to speculate a canopy.

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BOUNDING FRAME STUDIES

This is the second style of approach for aggregation. The folds and pinches of a surface is constrained within a bounding frame. This frame is then aggregated with the folded surface. Attempt to achieve a more strategists system towards designing and fabrication

194

STRUCTURE CURVE STUDY

This is the third style of approach for aggregation. The surface have another pocket to cling on to a structure frame which acts as a guide curve for the aggregation and growth direction.

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CHAPTER |9 BOUNDING FRAME STUDIES

SURFACE AGGREGATION STUDY BOUNDING FRAME STUDIES PIPE PINCHING STUDIES BOUNDING FRAME AGGREGATION PHYSICAL STUDIES DIGITAL SPECULATION

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[ SURFACE AGGREGATION STUDY ] BOUNDING FRAME STUDIES

SURFACE AGGREGATION WITH BOUNDING FRAME

Square base pyramid

Octahedron

Polyhedron

Dodecahedron 198

PIPE AGGREGATION STUDY

Polyhedron

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[ SURFACE AGGREGATION STUDY ] PIPE PINCH STUDY

DIGITAL SIMULATION

C o ntro l l i ng the chain link pipes and simul ati o n the fo l ds a nd pi n c hes. T hese chain links are a l s o pi nched to t he bo un di ng f rame giving it possibili ty fo r a g g regati on th ro u gh chain connection.

Square base pyramid

FOLD 1

FOLD 2

FOLD 3

FOLD 4

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[ SURFACE AGGREGATION STUDY ] BOUNDING FRAME AGGREGATION STUDY

DIGITAL SIMULATION

The bo un di ng f rames are ag gregated w i t h the se l f pi nched pipe chain links. The se c ha i n l i nks f ur ther connect with i t s re spe c ti ve neig hbours to for m a g row i n g a g gre gating component.

1 BOX

3 BOX- CENTRE

4 BOX

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[ SURFACE AGGREGATION STUDY ] AGGREGATION STUDY

SURFACE AGGREGATION WITH BOUNDING FRAME

Different folding surfaces within a bounding frame catalogue.

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[ SURFACE AGGREGATION STUDY ] AGGREGATION STUDY

SURFACE AGGREGATION WITH BOUNDING FRAME

Aggregation of one of the developed catalogue.

80 CM

45 50 CM

206

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[ SURFACE BASED MODELLING ] COMPONENT RESEARCH _ ELLIPSE

BOUNDING FRAME PINCHING AND AGGREGATION.

The process involves folding a huge surface within a bounding frame. This compressed component in the frame is then aggregated with more frames of the similar component.

45 C M

M 45 C

208

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[ SURFACE AGGREGATION STUDY ] AGGREGATION STUDY

SURFACE AGGREGATION WITH BOUNDING FRAME

210

Column speculation study

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[ SURFACE AGGREGATION STUDY ] AGGREGATION STUDY

AGGREGATION OF ELLIPSE WITH BOUNDING FRAME

Wall speculation study

212

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[ SURFACE AGGREGATION STUDY ] AGGREGATION STUDY

214

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[ SURFACE BASED MODELLING ] COMPONENT RESEARCH

SURFACE STUDY

With the developed frame study, the research looks into different possibilities of surface which are folded with in the frame.

45 CM

220

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[ SURFACE BASED MODELLING ] COMPONENT RESEARCH

SURFACE STUDY

Exploded isometric of the column composition showing connections.

222

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[ SURFACE BASED MODELLING ] COMBINATION OF THE TWO STUDY APPROACHES.

SPECULATION STUDY

This speculation incorporates the early studies of surface aggregation with and without the bounding box. CATALOGUE OF COMPONENT

224

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[ SURFACE BASED MODELLING ] COMBINATION OF THE TWO STUDY APPROACHES.

SPECULATION STUDY

This speculation incorporates the early studies of surface aggregation with and without the bounding box. This looks at various column proposals.

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CHAPTER |10 STRUCTURE CURVE STUDY

SURFACE AGGREGATION STUDY DIGITAL STUDY PHYSICAL HALF COLUMN CHAIR PROTOTYPE DIGITAL SPECULATION

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[ SURFACE AGGREGATION STUDY ] ANIMATION OF FOLDED COMPONENTS

CANOPY AGGREGATION_CATALOGUE

232

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[ PHYSICAL COMPONENT ]

234

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[ SURFACE AGGREGATION STUDY ] STRUCTURE + AGGREGATION

GROWTH AND CONNECTIONS- PROTOTYPE 01 _HALF COLUMN

This is the third style of approach for aggregation. The surface have another pocket to cling on to a structure frame which acts as a guide curve for the aggregation and growth direction. CONNECTING POINTS

connect Fold Back

236

Fold Back

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[ SURFACE AGGREGATION STUDY ] STRUCTURE + AGGREGATION

GROWTH AND CONNECTIONS- PROTOTYPE 01 _HALF COLUMN

These are studies of the other types of columns which can be made with the same surface and structure. The variations are achieve through changing the pinching and folding directions. CONNECTING POINTS

Ellipse 1 Fold Structure Ellipse 2

Fold Ellipse 3 Ellipse 4

Fold Ellipse 1

Ellipse 2

Ellipse 3

Fold Ellipse 4

238

Ellipse 1

Ellipse 2

Ellipse 3

Ellipse 4

Ellipse 1

Ellipse 2

Ellipse 3

Ellipse 4 AD RC5 & 6 Composite Skin | UCL - Bartlett 239

[ FABRICATION STUDY ] SUB STRUCTURE CONNECTIONS

GROWTH AND CONNECTIONS- CHAIR FABRICATION

The sa me a pp roach is used to fabr icate a c ha i r.

FLEXIBLE TUBES SS FRAME

2.7m BACK REST

0.45m SEAT 240

1.3m

BASE

STRETCH TEST

Fold Front

Fold Back

Fold Front

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[ FABRICATION STUDY ] SUB STRUCTURE CONNECTIONS

GROWTH AND CONNECTIONS- CHAIR FABRICATION

242

CONNECT WITH ITSELF

CONNECT WITH FRAME

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[ FABRICATION PROTOTYPE ] CHAIR

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[ DIGITAL STUDY ] CURVE BASED GENERATION

STRUCTURE STUDY

A s eri e s o f si m ulation is done to gene rate c ur ve s which could ref lect the i de a o f struc ture for sur face compone nt a g gre gati o n.

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LOCK POINTS PINCH POINTS

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[ DIGITAL STUDY ] CURVE BASED GENERATION

STRUCTURE STUDY

D i ffe re nt set up are tr ies to achieve va r i ati o n s i n growth and thickness.

LOCK POINTS PINCH POINTS

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[ DIGITAL STUDY ] CURVE BASED GENERATION

STRUCTURE STUDY

I n add i ti o n to this there are studies re l ate d to the connection between a col umn a nd a ceiling. T hese studies a re the n use d to speculate a column a nd a c e i l i ng p rototype.

250

LOCK POINTS PINCH POINTS

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[ DIGITAL STUDY ] SUB STRUCTURE CONNECTIONS

GROWTH AND CONNECTIONS- COLUMN FABRICATION

The ge ne rate d cur ves are used as g u i de c ur ve s for the sur face to cling o n to a nd atta c h with the other neighbo ur i ng co m po nents.

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EXPLODED ISO OF COLUMN CONNECTION.

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[ ARCHITECTURAL SCALE STUDIES ] DESIGN DEVELOPMENT LOGIC

CO LU M N A N

WA L L

CO LUM N

254

PAVI L I O N

C AN OPY

CO M P O NE NT AG G R EG AT I O N O N ST R U C T U R E

N D C E ILIN G

BO U ND I NG F R AME AG G R EG AT I O N

PIPE COMPON E N T CON N EC T ION

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[ ARCHITECTURAL SCALE STUDIES ] WALL SPECULATION

The digital speculation of a wall peiece is a combination of the three strategies developed during the research.

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[ ARCHITECTURAL SCALE STUDIES ]

258

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[ ARCHITECTURAL SCALE STUDIES ]

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CHAPTER |10 ARCHITECTURE SPECULATION

SITE SELECTION DESIGN PROPOSAL

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[ SITE SELECTION ]

A rchi te c tu ra l proposal at T he M useum o f Mo dern A rt: Mo MA PS 1 L o cati o n: L o ng Island C ity : NY 11101

266

Pro po sal Sketch

A bo ut MOMA Ps1 Pro po sal fo r â&#x20AC;&#x153; T he Yo un g Arch itect s Pro g ram fo und ed by Mo MA and Mo MA PS1 is co m m itted to o fferin g em erg ing architect u ral talent t he o ppo rt u nit y to desig n and present inn ovat ive pro ject s. To develo p o rig in al desig ns fo r a tem po rar y, o utdo o r installat io n at Mo MA PS1 t hat prov id es respite wit h sh ad e, seat ing , and water.â&#x20AC;? T he develo p ed m aterial system addressed to requ irem ent s o f t he Mo Ma. A shad ed seat ing shelter allowing peo p le to m ove aro und and interact wit h t he bo dily rig id rub ber y surface, a dialo g u e o f t he f lesh and t he m em brane. AD RC5 & 6 Composite Skin | UCL - Bartlett 267

[ ARCHITECTURAL PROPOSAL ]

268

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[ ARCHITECTURAL PROPOSAL ]

SECTION AA’

SECTION BB’ 270

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[ ARCHITECTURAL PROPOSAL ]

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[ ARCHITECTURAL PROPOSAL ]

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Composite [Skin] Research Cluster 5&6

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