BPro RC 5+6 2016/17_Fluid Deformation

Fluid Deformation Research Cluster 5&6

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

Fluid Deformation Dynamic Casting in Water Beads

Tutors: Daniel Widrig Guan Lee Soomeen Hahm Stefan Bassing Igor Pantic Adam Holloway TEAM MEMBERS: Bicen Song Jiamin Lin Jieyu Shi Yunhao Tang

Introduction The project is mainly about casting aluminium into water beads, controlling and guiding the aluminium liquid to obtain a desired piece to make the beautiful organic shape not only ornamental but also more importantly functional. Water beads is the gel which contains a large amount of water. Different from traditional metal casting, casting in water beads just takes few seconds to cool down and the water beads can be easily removed as it is soft and fragile.

Firstly, we want to control the shape and guide the aluminium liquid to obtain a desired curve shape. We have a slightly success but the set up is quiet complex and it is hard to make larger piece in the future. Then we concentrated more on the combination with timber, hoping to make aluminium piece as a joint part. We poured aluminium liquid around the timber and join them together external. Later we found it is much better to pour aluminium inside the timber and join them internal.

In this project, aluminium works as a free form joint part to assemble wood structure into a large-scale building structure. Through this way, aluminium is well controlled, following along the channels and creating an organic-shaped

joint part at the holes. This joint system is based on the inner channel, which guides the aluminium to connect every component. To get the joint, the method of drilling channels inside wood sticks and making holes at the joint part was experimented. When casted into the top holes, aluminium flows along the channels and goes out at the exit holes to the water beads. As a result, the aluminium came in and out of the channels and solidified, wrapping the timber tightly.

Compared with design applications of casting in history, the design applications of open mould casting are innovative and has its advantages. The patterns are not designed intentionally but the result of the reinforcement of joints, which means the organic patterns are not only decorative ornaments. And compared with current prefabricated joints, open mould casting joints are able to be finished by the same setup. In other words, the moulds of all joints are the same: an open surrounding with the water beads (in our case it is water bead but it can be something else to achieve industrial production). This can bring more freedom for the design of the form.

Content 1 INITIAL APPROACH 1.1 Reference

1.2 Initial Study

5 FABRICATION EXPLORATION JOINT

5.1 Pouring outside

- Tools & Material Exploration

- Joint

- Initial Attempts

- Assembling

2 MATERIAL STUDY

- Digital Exploration 5.2 Pouring inside

2.1 Metal Evaluation

- Spatial Joint

2.2 Water Beads Evaluation

- Linear Joint

2.3 Water Condition

5.3 Surface Combination

2.4 Arrangement Study

5.4 Pure Aluminium Tests

3 CRAFT DEVELOPMENT

6 FABRICATION EXPLORATION

3.1 Casting Craft

- Vertical & horizontal casting - Multi-casting - Geometry Study 3.2 Parameter | Subtractive Obstacle 3.3 Parameter | Additive Obstacle 3.4 Parameter | Foam Guidance 3.5 Turbulence

4 FABRICATION EXPLORATION CURVE 4.1 Sand Mould 4.2 Clay Mould 4.3 Foam Guidance 4.4 Rope Guidance 4.5 Bending & Combining 4.6 Wood Stick

6.1 Column Prototype 6.2 Stool 1 6.3 Stool 2

6.3 Multi-casting Column 6.4 Chair

7 DESIGN APPLICATION 7.1 Grid Study

- Different Grid Combination - Selected Grid - Chair - Table - Staircase 7.2 Facade 7.3 Spatial Design

8 ARCHITECTURAL DESIGN

Chapter 01

INITIAL APPROACH Initially, molten sugar was casted into ice, making organic texture. However, sugar is not a suitable material for architecture as it is not stable. Thus, metal can be better choice.

However, it is quiet difficult to melt aluminium in initial stage. Low melt point alloy was first used instead of meta. Later, the kiln solve the problem of melting aluminium and the result of aluminium casting is much better than alloy.

01 INITIAL APPROACH

T E X T U R E

[ Reference ]

M E T A L

Figure1: Anthill Casting

Figure2 : Pewter Stool (2006), Caerhays Beach, Cornwall, UK, 380 x 440 x 440

C A S T I N G

In metalworking, casting means a process, in which liquid metal is poured into a mould, that contains a hollow cavity of the desired shape, and then allowed to cool and solidify. The solidified part is also known as a casting, which is ejected or broken out of the mould to complete the process. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods. Â Casting processes have been known for thousands of years, and widely used for sculpture, especially in bronze, jewelry in precious metals, and weapons and tools. Traditional techniques include lost-wax casting, plaster mold casting and sand casting.

Figure3: Metal Casting

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Figure 4: Kaarsrecht Stool (2009), Pascal Smelik

Figure 5 : Prada Sponge (2002), OMA, Los Angeles, USA

Figure 6: Lighting sculpture (2016), Omer Arbel, Barbican , London, UK

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01 INITIAL APPROACH

[ Reference ] Unlike some traditional method of casting, pouring metal liquid into a solid and unremoveable mold, we found an interesting video on YOUTUBE, the man poured liquid molten aluminium into water beads, and he removed water beads easily just using hydraulic giant to wash the beads away. Also, the shape of the casting result is organic and beautiful.

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01 INITIAL APPROACH | INITIAL ATTEMPTS

[ Tools & Material Exploration ] Three different ways were tried to melt aluminium during the study. y comparison, kiln is the most efficient appliance and can reach temperature around 1000℃. Both homemade foundry and electric can only reach the temperature around 200℃. Three kinds of material are explored during the experiment. Though alloy has the lower melting point, it is fragile.

1. Homemade foundry & 2. Electric foundry 3. Kiln & 4. Recycled Cans 5. Low melt alloy & 6. Aluminium

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01 INITIAL APPROACH | INITIAL ATTEMPTS [ Can & Homemade Foundry ]

First, play sand and plaster of paris were mixed to make a homemade foundry and charcoal was used as fuel. Hair dryer was used to blow oxygen into the foundry. The aluminium was about to melt, but failed to become liquid because it is hard to get the operating temperature of aluminium which is 100 degrees higher than the melting temperature.

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01 INITIAL APPROACH | INITIAL ATTEMPTS [ Alloy & Electric Foundry ]

Initially, problems came with melting aluminium. Due to the limitation of facilities, tests of some alloy with low melting point was tried at first. In the same way, alloy was casted into water beads, and gained some sculpture showed below. However, the material of alloy is not as suitable as aluminium because alloy is more fragile and its surface is not smooth.

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01 INITIAL APPROACH | INITIAL ATTEMPTS [ Aluminium & Kiln ]

Later, kiln was used to melt aluminium, and we got much better consequence. The pieces are smoother and stronger. Then series of tests with aluminium was tried, like using foam tube or ball and rope to guide the aluminium liquid, combining the aluminium and timber to make the result more controllable.

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Chapter 02

MATERIAL STUDY Mainly, there are three influence factors of the consequence: metal, water beads and water. At first, in order to contrast the result of different kinds of metal, alloy of low melt point and aluminium were tried. Different size of water beads and various arrangement of water beads are another element. Moreover, aluminium was poured into water beads with different temperature of water and without water to test the influence of water.

02 MATERIAL STUDY

[ Metal Evaluation ] Above all the experiment, an overall conclusion was made of three different kinds of metal. Sugar is cheap and easy to get, however its fragility and density is relatively low, which may cause the result of instability and hard to flow along the gap between the water beads. Aluminium is a good material, it has relatively high permeability, fragility and density, and the price is acceptable, while the melt point is relative high and we need to use some specialised facilities to melt it. Low melt alloy 1 has a special characteristic of low melting point, and its price, permeability, density and fragility is good. While the low melt alloy 2 contains lead, which is a toxic substance, and its melt point is too low, which can cause instant solidify when it touches the water.

Material 1 Low Melt Alloy1(95% Tin Mellt Point: 236℃

Melt Time: Permeability: Fragility: Price:

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Material 2 Low Melt Alloy2 (With Lead) Mellt Point: 188℃

Material 3 Aluminium Mellt Point: 660.3℃

Melt Time:

Melt Time:

Permeability:

Permeability:

Fragility:

Fragility:

Price:

Price:

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02 MATERIAL STUDY

[ Water Beads Evaluation ] The size of water beads might affect the consequence of experiment. Based on Term1’s study, three different sizes of water beads (8mm, 15mm, 40mm respectively) were chosen to analyze the texture of aluminium. According to the test, the casting with small size water beads has the stronger connection and high permeability, and the fragility is comparatively low as well. Overall, 15mm is the most suitable diameter according to the outcome.

Water Beads: Small Size(8mm) Expanding time:

4 Hours

Fragility:

30%

Aluminium:

Connection:

90%

Permeability:

70%

Water Beads: Small Size(15mm) Expanding time:

8 Hours

Fragility:

30%

Aluminium:

Connection:

90%

Permeability:

70%

Water Beads: Large Size35mm) Expanding time:

20 Hours

Fragility:

80%

Connection:

60%

Permeability:

70%

Water Beads: Large Size35mm)

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Size

Texture

Connection

Permeability

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02 MATERIAL STUDY

[ Water Condition ] In the water condition test, aluminium was poured into medium size (15mm) and large size (40mm) water beads with water and without water. The depth that aluminium reached in the water was measured to test the permeability. Aluminium poured in water beads with water has the better permeability.

Surfaceďźš

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Water Beads: Medium Size Water Condition: Without Water Relatively Rough Surface

Surfaceďźš

Permeability:

Permeability:

Fragility:

Fragility

Water Beads: Medium Size Water Condition: With Water Relatively Smooth Surface

Surfaceďźš

Water Beads: Large Size Water Condition: Without Water Relatively Rough Surface

Surfaceďźš

Permeability:

Permeability:

Fragility:

Fragility:

Water Beads: Large Size Water Condition: With Water Relatively Smooth Surface

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02 MATERIAL STUDY

[ Arrangement Study | Small & Large Size ] Various combination of different size of water beads were tested, contrasting the different texture within one piece. When aluminium flows along the larger size of water beads, it goes quite fast so the structure of this part is unstable. On the contrary, aluminium liquid travels relative slow so more aluminium stays between the smaller beads, leading to stronger part.

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1

2

3

4

Perspective

Front

Right

Prototype

Pattern1

Pattern2

Pattern3

Pattern4

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Chapter 03

Craft Development After material study, we started to find ways to control the shape of aluminium, by changing the casting method and material casted into.

Also some obstacle were added like tube or foam in order to change and guide the path of aluminium liquid. Due to the successful experiment of foam tube guidance, further experiments on how to guide curving aluminium were explored. Based on it, interesting curves were generate digitally by Maya.

03 CRAFT DEVELOPMENT [ Casting ]

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Vertical Casting

Top

Horizontal Casting (Linear)

Top

Vertical Casting (Curve)

Top

Frame 035

Frame 107

Frame 187

Frame 228

Frame 262

Frame 019

Frame 042

Frame 071

Frame 121

Frame 154

Frame 017

Frame 035

Frame 068

Frame 94

Frame 123

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03 CRAFT DEVELOPMENT

[ Multi-casting ] Besides casting in one time, multi-casting is one to produce more complex shapes. As shown in the diagram, Through five times casting, a triangular pyramid was done.

1. Cast a triangle 2. Rotate the triangle 3. Cast the other 2 lines 4. Replace the subject 5. Cast the last line to complete

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03 CRAFT DEVELOPMENT

[ Component | Basic Geometry ] Through multi-casting, more geometry can be created. Besides casting in a plane, spatial geometry could also be made. Several basic geometries are listed below.

Stick

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Perpendicular

Curve

Stereoscopic Structure1

Stereoscopic Structure2

Ingredients: Aluminium Water Beads: 1.5cm Water Condition: Without Water Making Time: 0.5 hours Size: 22cm*22cm*18cm

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03 CRAFT DEVELOPMENT

[ Parameter | Subtractive Obstacle ] We tested different shape of material which we can cast into. Aluminium was casted into two kinds of pasta, linear shape and curvy shape. Although the piece is quite small, but interesting texture could be seen in this experiment.

1. Melt aluminium 2. Put pasta into the cup 3. Cast aluminium into pasta

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Ingredients: Aluminium Guidance: Pasta Water Beads: 1.5cm Water Condition: Without Water Making Time: 0.5 hours Size:6cm*2cm*4cm

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03 CRAFT DEVELOPMENT

[ Parameter | Additive Obstacle ] Attempt was made to combine a smooth surface with beadstexture piece. Firstly, make a sand mode by pressing a wood brick. Then pour molten aluminium directly into the sand mode.

As there is no water to cool down the aluminium, it takes longer time for aluminium to turn into solid. Before it becomes solid, insert beads-texture piece into the aluminium liquid and hold it for a while. Finally, two piece were combined together.

1. Press wood bick into sand 2. Remove wood brick 3. Cast aluminium into the gap 4. Stick another piece before solidify

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[ Parameter | Foam Guidance ] In order to control the path of aluminium flow, foam tubes were set in water beads to lead the path. When aluminium liquid came across the foam tube, it has the tendency to flow along it, making some interesting path with the form of foam tubes.

Ingredients: Aluminium Guidance: Foam Water Beads: 1.5cm Water Condition: With Water Making Time: 0.5 hour Size: 10cm*10cm*20cm

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03 FORM GENERATION

[ Turbulence ] Based on the experiment on controlling aluminium, some digital exploration were explored as well. A series of curvy lines were generated with the logic of turbulence in Maya. Parameter were changed to make more possibility. These curves were utilized to make some spatial area.

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03 FORM GENERATION

[ Turbulence | Parameter ] In computer, we use Maya to generate interesting curves, using the effect of Turbulence. By changing the parameter like Magnitude and Frequency of Turbulence, we can get different form. Additionally, we can add boundary or more particle to make specific form and surface.

nParticle Count: 2 Turbulence Magnitude: 75 Turbulence Frequency: 0.05

nParticle Count: 2 Turbulence Magnitude: 1500 Turbulence Frequency: 0.04

nParticle Count: 2 Turbulence Magnitude: 300 Turbulence Frequency: 1.00

nParticle Count: 3 Turbulence Magnitude: 100 Turbulence Frequency: 0.60

nParticle Count: 3 Turbulence Magnitude_1: 100 Turbulence Frequency_1: 0.60 Turbulence Magnitude_2: 200 Turbulence Frequency_2: 1.00

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03 FORM GENERATION

[ Growth Logic | Linear ] In Turbulence, curves are generated from one point, and grows in a spiral way like turbulence. Parameters are changed to obtain the desired shape. In the diagram below, the curves grows in a linear logic..

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03 FORM GENERATION

[ Growth Logic | Surface ] Different from the previous one, in this logic, curves grows in a surface logic. Curves are emitted from one basic curve, and then generated in a surface way. The work in this example has more levels than the one generated in linear logic.

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03 FORM GENERATION [ Pavilion ]

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Chapter 04

Fabrication Exploration Curve In order to realize digital work in physical test, foam tube and ropes were used to guide aluminium liquid. However, the set up of ropes is complex and it is hard to make large piece in the future, so straight timber sticks were tested instead to guide aluminium.

04 FABRICATION EXPLORTION | CURVE

[ Sand Mould ] In order to create a curve shape piece, casting in a sand mould was first tried. Tube and wire were cut into proper length and tied together. They were put vertically in a box and then the box was filled with sand . Finally, tubes were taken out and the box was then filled in water beads.

1. Make the tube 2. Set the tubes and fill in the sand 3. Get the tubes out 4. Fill in the water beads

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04 FABRICATION EXPLORTION | CURVE

[ Clay Mould ] Besides sand mould, clay mould was also tried to control aluminium, for clay surface is much smoother than sand. The outcome is much better. We got a curve shaped aluminium piece and t texture is also clear. However, aluminium still cannot go deep in the clay mould.

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[ Curve Attempt | Foam Guidance ] Due to the failure of casting in sand mode, we tried foam tube to guide the aluminium liquid based on the experiment of foam guidance which we did before. In terms of the set up, a wood frame was set up and grids were made on top, middle and bottom parts to fix the foam tubes.

1. Make a box 20mm*20mm*40mm 2 . Make grid on top, middle and bottom part 3. Fix foam tube 4. Put in water beads

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04 FABRICATION EXPLORTION | CURVE

[ Curve Attempt | Foam Guidance ] Foam tube was melted and aluminium liquid went into the tube, creating a fragile connection part which is not expected. However, the overall shape has a curved tendency, which demonstrated that aluminium can be guided successfully if the material cannot be melted.

1. Make a frame 2. Nail to fix the string gird 3. Weave string to make grid 4. Fix the foam tube

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Ingredients: Aluminium Guidance: Foam Water Beads: 1.5cm Water Condition: Without Water Making Time: 5 hours Size: 20cm*20cm*40cm

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04 FABRICATION EXPLORTION | CURVE

[ Rope Guidance ] Later, foam tubes were changed into ropes, as rope would not be burned when dipped into water. Using the same wood frame, the ropes were fixed and an overall curving path constrained for aluminium liquid. Consequently, one of the aluminium branch flowed along the ropesďźŒcreating a beautiful curving aluminium with beads- and rope- texture. While there was still a amount of aluminium block up at the top part, we assume it might due to the density of the ropes.

1. Rope Setup 2. Put in water beads 3. Outcome after pouring in aluminium 4. Aluminium flows along the rope

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04 FABRICATION EXPLORTION | CURVE

[ Rope Guidance ] Most of aluminium was block up on the top part. Some streams of aluminium flows along the ropes, and only a few aluminium goes deep down to the bottom. However, a problem remained: there was no connection design in this proposal, and it was relatively hard to make a larger piece. Besides, the hollow piece cannot be the main structure, since aluminium itself is not strong enough.

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Ingredients: Aluminium Guidance: Foam (left) & Rope Water Beads: Medium Size Water Condition: Without Water Making Time: 5 hours Size: 20cm*20cm*40cm AD Research Cluster 5&6 | UCL Bartlett

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04 FABRICATION EXPLORTION | CURVE

[ Bending & Combining ] The attempt of curving guidance was not so successful, we began to study the additive element. We first thought about combing aluminium tube by casting aluminium in water beads. However, instead of being constrained by aluminium tube, the liquid flows freely. Also, because the cooling time of aluminium is too short, just little of surface of aluminium tube is melted, so the combination is not very successful.

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04 FABRICATION EXPLORTION | CURVE

[ Pouring Outside | One Stick ] In order to make larger piece as well as guide aluminium, wood was added. Aluminium was poured into one stick, aluminium still flowed freely.

Wood Sticks (Hollow)

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Setting

Aluminium Casting

Remove Sticks

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04 FABRICATION EXPLORTION | CURVE

[ Pouring outside| Several Sticks ] Aluminium was poured into a branch of wood stick, creating a joint outside. These experiments gave us the inspiration to use aluminium as a joint system to combine wood sticks. However, the amount of aluminium cannot be calculated well. Besides, removing the wood sticks is time-consuming. And the angle is inaccurate.

Wood Sticks (Hollow)

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Setting

Aluminium Casting

Remove Sticks

Insert Solid Stick

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Chapter 05

Fabrication Exploration Joint Because of the successful combination with timber, we began to study how to use aluminium as a joint part, and how to combine it with wood structure. At the beginning, we casting aluminium outside the timber, wrapping the wood and join them. Later, another method was experimented by drilling a hole inside wood sticks and making holes at the joint part.

05 FABRICATION EXPLORTION | JOINT

[ Pouring Outside | Joint Study ] In order to improve the joint system of aluminum with wood sticks, more experiments were did to do the joint study. In this experment, wood sticks were put in the box with angles. After castin, wood was removed. Then, another stick was inserted to connect with another.

1. Wood Sticks (Hollow) 2. Setting 3. Aluminium Casting 4. Remove Sticks 5. Insert Stick to Connect

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05 FABRICATION EXPLORTION | JOINT

[ Pouring Outside | Joint Study ] Compared with traditional method of making joint, the way of using aluminium has lots of advantages. Firstly, it can join several sticks vertical and horizontal at any kind of arrangement. Secondly, pouring aluminium around the sticks is able to combine intersectional sticks no matter they are adhered to each other in advance. With similar logic, the intersectional sticks can be combined with each other at any angle, which can make the form more interesting.

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05 FABRICATION EXPLORTION | JOINT

[ Assembling ] With the logic of removing hollow stick and inserting solid one, we assembled a larger piece. We used the piece made by one stick as a finished part. However, this method also has shortcoming, as we pouring aluminium at the stagger point, some aluminium flows inside the hollow stick and the hollow sticks become irremovable.

Line

Joint

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Finish

Joint

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05 FABRICATION EXPLORTION | JOINT

[ Assembling ] Combined the previous experiments, we come up with a assemble plan. Placing four sticks as a timber group, joining four groups by pouring them at stagger point. Leaving one of the groups as a connection, and joining sticks of other groups by pouring aluminium around them. In this way, we can assemble a large scale piece and rotate each component with any angle.

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05 FABRICATION EXPLORTION | JOINT

[ Digital Design I Stairs ] With same logic, the joint casted by aluminium can combine wood with any angle. Compared with the traditional joint system by using angle brackets to fix the angle, the joint system of casting aluminium internally is extremely efficient in the non-rightangle casting.

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05 FABRICATION EXPLORTION | JOINT

[ Pouring Inside | Joint Study ] We began to study pouring aluminium inside timber, hoping to join timber internally. At first, putting four solid sticks and placing wood chip between these sticksďźŒmaking holes on the surface.

Consequently, aluminium liquid flows from internal to external, wrapping the timber tightly.

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05 FABRICATION EXPLORTION | JOINT

[ Pouring Inside | Joint Study ] Different size of holes on surface will lead to different result. Small holes might cause the aluminium liquid hardly flows out, while larger holes will result in mass around timber, thus the proper size of holes is important to the consequence.

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05 FABRICATION EXPLORTION | JOINT

[ Pouring Inside | Surfafce ] We also tried to combine surface together. Putting several surface together and drilling holes to make aluminium flow through the holes and grab the surface. In the project of larger scale, we can insert sticks at the surface centre, using the sticks as a connection with next piece.

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05 FABRICATION EXPLORTION | JOINT

[ Pouring Inside | Four Direction Joint ] by pouring aluminium inside the sticks. Firstly, drilling internal channel and holes on surfaces, placing sticks below the holes, making aluminium liquid flow wrap the stick below and joining them together. Compared with the method of drilling nail, the limitation is that the sticks below can not be jointed with any angle.

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05 FABRICATION EXPLORTION | JOINT

[ Pouring Inside | Linear Joint ] With similar logic, we can combine sticks with different angle, making polyline. And this time, funnel was used to avoid mass top because aluminium can be poured directly into the timber.

This method is able to make aluminium twine around the timber, result in better combination. During the process of poring aluminium, aluminium first flows out from the bottom holes, creating the joint, and then flows out the top hole.

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05 FABRICATION EXPLORTION | SIMULATION

[ Stick Simulation ] The simulation method is inspired from Galton-Watson Trees and DLA logic. A started seed point is set in a cloud of points, then a series of progenies is generated with the random number of points. Finally, Cocoon (curve charge and point charge function) is used to warp the dendritic lines with the desired mesh surface.

Making holes at joint part (hole diameter: 1 mm 3 mm 5 mm)

Making slot on the surface (slot diameter: 1 mm 3 mm 5 mm)

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Line loops in random points (Looping times: 1 time 4 times 8times)

Pipe the looping (Curve charge radius:

Subtract the balls (Ball radius:

lines 0.03 0.09 0.15)

0.07 0.09 0.10)

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05 FABRICATION EXPLORTION | SURFACE

[ Cast into sticks ] With the idea of creating surface, aluminium was casted vertically into several wood stick on a board. Aluminium wrapped the sticks and created a flat surface with interesting texture of water beads.

However, in this method, aluminium cannot go widely, it stacks in a certain area.

1. Drill holes on one board 2. Screw wood sticks on the board 3. Cast through a hollow wood stick 4. Aluminium wrap the sticks and create a surface

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05 FABRICATION EXPLORTION | SURFACE

[ Casting with a panel ] In order to get a thinner and larger surface, aluminium was casted into a wood stick with slots which was stick to a wood panel.

Aluminium spills out through the slots and flows out vertically, sticking to the wood panel as it went through the channel. Aluminium was controlled by the gravity.

1. Aluminium spills out on the board 2&3. Details of the surface

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05 FABRICATION EXPLORTION | SURFACE

[ Separate Into One ] Using aluminium as a joint part to comebine all the seperate pieces together is another logic to make flat surfaces. We lazer cutted all the small components and cut an ashed pattern to fix the position. Cast aluminium through the channel and the wood pieces are combined.

1. Componet and ashed board 2. Put the coponent into position 3. Original shape 4. Casting Channel

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05 FABRICATION EXPLORTION | PURE ALUMINIUM

[ Test 1 ] The method is inspired from the previous experiment which combining several separated timber as a flat surface. The wood channel is displayed below, while at this time, the wood would be easier to taken out because the aluminum would not flow through the timber. The timber merely plays an role of a open mold.

1. Set up plan 2. Set up section 3. Cating outcome

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[ Test 2 ] In this test, the timber and aluminium play the role for the opposite. The timber is a join part and pure aluminium becomes the structure. There are two wood mould, one is used to shape the aluminium and would be remove afterwards. Another one is used as the join part. Inserting the former one into the latter one, drilling holes above the junction part, the aluminium flow is able to join the wood part and pure aluminium part together through the channel inside. With same logic, different directions of the aluminium can be combined together.

1. Set up plan 2. Set up section 3. Cating outcome

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05 FABRICATION EXPLORTION | PURE ALUMINIUM

[ Test 3 ] Besides the water beads, we also tried to cast aluminum into wood mold inside the sand. The wood mold is buried in the sand, and due to the extremely high temperature, the wood buried and leaving an interesting texture on the surface.

俎攚

1. Laser cut wood piece 2. Bury the set up in the sand 3. Cast aluminium 4. Cool down and take piece out

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Chapter 06

Physical Fabrication Based on the research before, we designed a column whose size is around 0.6 meter high.

We first tried traditional way to cut the wood by wood machine, then glued it. Consdering that we may do something larger scale in the future, we may try CNC cutting in the future.

06 PHYSICAL FABRICATION | COLUMN

[ Casting Process ] The column can be divided into top part and bottom part. Each part has four legs. Aluminium was used to combine separate sticks, which works as a joint system. Channels are designed inside the wood sticks by drilling holes inside and outside.

1. Bottom part casting 2. Reverse the bottom part and cast again 3. Assemble the top part to the bottom part 4. Top part Casting

06 PHYSICAL FABRICATION

[ Casting Simulation ] The casting progress was simulated by grasshopper. The casting time and casting amount was simulated in each channel. First, the bottom part was put in the box which is filled with water beads.

After casting, the bottom part was reversed, and casted again through four channel to combine. Finally, the top part was combined with same logic.

06 PHYSICAL FABRICATION | COLUMN [ Fabrication Progress ]

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1. Cut the wood stick into pieces

2. Cutted wood sticks

3. Use the angle cutting machine to fix the angle

4. Angle-cutted wood sticks

5. Drill holes in the middle of the stick to make channel

6. The channel

7. Burn the wood sticks into black

8. Assemble the wood sticks

9. Glue them together

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06 PHYSICAL FABRICATION | COLUMN [ Bottom Part Casting ]

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06 PHYSICAL FABRICATION | COLUMN

[ Top Part Casting ] After combine the bottom part by casting, the for sticks of the top part were assemble to the bottom part one by one. After that, cast aliminium to the holes of channels to streghthen the connection between the two parts.

1-4. Assemble the top part to the bottom part one by one 5. Cast aluminium through the channels

06 PHYSICAL FABRICATION | COLUMN [ Column Design ]

06 PHYSICAL FABRICATION

[ Craft Comparision ] We tried three different crafts in fabrication, namely drilling, CNC, and laze cutting. Among all, laser cutting is the most suitable way to do fabrication since it is quick, precise and easy to do.

Drilling

CNC

Lasercutting

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1. Drilling 2. CNC 3. Laser cutting

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06 PHYSICAL FABRICATION | PROTOTYPE STOOL1

[ Design Principle ] In order to test the bearing capacity, we made a prototype stool.

The stool is made by four legs and a sitting area, and a middle supporter is to strenghthen the bearing capacity. Slots are made at the joint area. When casted, aluminiun flows out at the slot, creating a joint system.

1. Original shape 2. Optimise legs and surface 3. Reenforce the middle part 4. Final Stool

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06 PHYSICAL FABRICATION | PROTOTYPE STOOL1

[ Component ] The stool consists of the saeting area, four legs, and a middle suporter. Each component is made by several sticks and combined together by casting aluminium.

Component 1: leg Component 2: middle suporter Component 3: surface

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06 PHYSICAL FABRICATION | PROTOTYPE STOOL1

[ Casting Channel System & Fabrication Progress ] First, four legs are casted one by one, and then assemble them with the middle column. Cast again into another channel of the fourlegs to combine the middle supporter with the legs. Last, cast aluminium into the hole of middle column to strengthen it.

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1. Make slot on the joint oart and glue them

2. Assemble wood stick into one leg

3. Cast aluminium into the hole and wrap the sticks together

4. Casting four legs one by one

5. Assenmble legs

6. Assemble the middle column

7. Cast through holes in leg to combine four legs with the middle column

8. Cast aluminium into the hole of middle column to strengthen it

9. Final stool

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06 PHYSICAL FABRICATION | PROTOTYPE STOOL1 [ Chair Design ]

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06 PHYSICAL FABRICATION | PROTOTYPE STOOL1 [ Sitting Test ]

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06 PHYSICAL FABRICATION | PROTOTYPE STOOL 2

[ Design Principle ] In an aim for designing joints of different direction, we also made an effort on organic shapes which has a similar language with the organic aluminium texture. A stool was designed based on this kind of language. Laser cut was used in fabrication.

06 PHYSICAL FABRICATION | PROTOTYPE STOOL 2

[ Fabrication Progress ] Three channels are designed to combine the three legs, creating some beautiful and interesting texture. We casted the three chair legs one by one. Then we reverse the stool and cast from the bottom in an aim for creating some organic branch form of aluminium to combine the top part.

1. Cast the first leg 2. Cast the second leg 3. Cast the third leg 4. reverse the stool and cast again

1. Laser cut the 6mm plywood

2. Glue the wood layer by layer

3. Stool before casting

4. Put the stool in bucket and fill in with bubbles.

5. Casting aluminium into the holess of three legs

6. Stool after 3 times casting

7. Revise the stool in the bucket

8. Cast aluminium into the hole at the bottom

9. Final stool

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06 PHYSICAL FABRICATION | PROTOTYPE STOOL 2 [ Stool Design ]

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06 PHYSICAL FABRICATION | PROTOTYPE STOOL 2 [ Sitting Test ]

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06 PHYSICAL FABRICATION | MULTICASTING

[ Design Principle ] In order to make larger piece, multicasting was explored during the physical experiment. We tried to use a container in certain size to cast a larger piece and remain the casting point always at the same point, since it is hard to fill in the container with water beads if the scale is too large.

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06 PHYSICAL FABRICATION | PROTOTYPE CHAIR

[ Design Principle ] Based on the previous physical exploration of 2 stools, linear language may better fit this kind of organic shape. Thus, a more complicated chair was designed to test more complex channels and bearing strength.

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06 PHYSICAL FABRICATION | PROTOTYPE CHAIR

[ Design Principle ] According to the previous chair design, we made some modifications on it. Instead of using all the wood sticks, we combine surface with wood sticks to explore more possibilities. Chair consists of three parts, legs, seating area and back. After casting legs and back, we combine them together with seating area by multicasting.

1. Original shape 2. Optimise loading area 3. Simplify chair legs and back 4. Optimize seating area

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06 PHYSICAL FABRICATION | CHAIR

[ Leg Casting Channel System ] The chair was made up with several components. Each components was first laser cut and then glued together. Eight channels are designed in the leg of chair to strengthen its structure. When casted, aluminium flows out and wrap the wood stick internally which makes the structure stable and strong.

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06 PHYSICAL FABRICATION | CHAIR

[ Back Casting Channel System ] Four channels are designed in the back of chair to combine the wood sticks and wood pannels in order to create a surface. When casted, aluminium flows out and wrap the wood stick internally which makes the strcuture stable and strong.

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06 PHYSICAL FABRICATION | CHAIR

[ Multicasting ] After the chair leg and back was casted, they were inserted into a wood panel. The wood works as the sitting area and conbines the other two parts.

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06 PHYSICAL FABRICATION | CHAIR

[ Seating Area Casting Channel System ] Seating Area works as a combination for the chair leg and back.

There are six channels in all. When casted, aluminium flows out and wrap the wood stick internally which makes the strcuture very stable and strong.

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06 PHYSICAL FABRICATION | CHAIR

[ Fabrication Progress ] Three channels are designed to combine the three legs, creating some beatiful and interesting texture. We casted the three chair legs one by one. Then we reverse the stool and cast from the bottom in an aim for creasting some organic branch form of aluminium to combine the top part.

1. Cast the bottom part chair leg 2. Cast the top part chair back 3. Combine two parts by multicasting

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1. Put the chair leg in the box and fill in with water beads

2. Cast aluminium into the channels one by one

3. Take out the leg part

4. Put the chair back in bucket and fill in with bubbles.

5. Casting aluminium into the channels

6. Take out the back part

7. Combine the leg and back by sitting area

8. Cast aluminium

9. Final chair

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06 PHYSICAL FABRICATION | CHAIR [ Sitting Test ]

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Chapter 07

Design Application

The previous physical fabrication gave a better understanding of this joint system. Based on that, more applications are designed, such as chair, table, column and stairs.

07 DESIGN APPLICATION | GRID STUDY

[ Grid 1 ] In order to study the form generated by different grid, three kinds of grid combination were tried. The first one is a composition of three types of cells. The form of chair is divided into chair leg, sit area and back to generate.

Initial Grid

Base Part Grid

Seating Area Grid

Back Grid

Guide Points to Grid Spcace

First Level Path

Second Level Path

Third Level Path

07 DESIGN APPLICATION | GRID STUDY

[ Grid 2 ] In this chair design, one kind of cell is duplicated and grouped.

With the same design logic, the chair is assembled by three parts of grid.

Initial Grid

Base Part Grid

Seating Area Grid

Back Grid

Guide Points to Grid Spcace

First Level Path

Second Level Path

Third Level Path

07 DESIGN APPLICATION | GRID STUDY

[ Grid 3 ] Based on the combination of three different elements and several control points, different form is generated and finally assembling a chair.

Initial Grid

Base Part Grid

Seating Area Grid

Back Grid

Guide Points to Grid Spcace

First Level Path

Second Level Path

Third Level Path

07 DESIGN APPLICATION | GRID STUDY

[ Chair ] After the previous grid study, one grid was selected. Grid was first placed into the chair shape. Points were generated in a boundary. Then, lines were generated from one anchor point to do the shortest walk.

Initial Grid

Bounding with Points

Anchor Point

Optimized Grid

Shortest Walk Path

Final Proposal

07 DESIGN APPLICATION | GRID STUDY

[ Table ] Grid was first placed into a table shape. In the shape, amounts of random points were generated. Four anchor points were selected at the table leg. Shortest walk was generated through these four points.

Initial Grid

Bounding with Points

Anchor Point

Optimized Grid

Shortest Walk Path

Final Proposal

07 DESIGN APPLICATION | GRID STUDY

[ Staircase ] According to the shape of staircase, grid was first placed. Points were generated in a bounding space. An anchor points were selected as the start point of the generation. Shortest walk was then generated from this point to the others.

Initial Grid

Bounding with Points

Optimized Grid

Shortest Walk Path

Anchor Point

Final Proposal

07 DESIGN APPLICATION | FACADE

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07 DESIGN APPLICATION | STAIRS

[ Design Principle ] In the stairs design, the logic of lines are extracted from the surface. Based on the walking path, we reshape the optimize the surface of steps. Then some of the lines on the surface are taken out and applied to wood structure. Finally, the aluminum are used for combining the wood together.

Original steps

From the body to the surface

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Subtract the walking path

Final Proposal

Reshape the steps

From the surface to the line

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07 DESIGN APPLICATION | STAIRS

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07 DESIGN APPLICATION | COLUMN

[ Design Principle ] The column design can be divided into three steps. The core structure is confirmed to bear the load at first, then some lines used as skin are added. Finally, the wood sheet is applied to connect these two parts. Through the channels inside the timber and the surface of wood sheet, aluminum is able to join these three parts together firmly.

Final Proposal

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Core Structure

Skin

Connection

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07 DESIGN APPLICATION | SPATIAL

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Chapter 08

Architectural Design In architectural design, form generation is mainly based on a mass of grid. The path is a kind of radial lines from the points where the column are places to the points on the surface of the floor. The spatial area was then optimised according to the function.

08 ARCHITECTURAL DESIGN

[ Detachment ] An overall shape was first designed to suit the space. Then, Floor and columns ere detached according to the load. Finally, the space was optimised by adding staircase and wall.

Overall Shape

Column Origin Point - 2nd Floor

Wall - 2nd Floor Load and Support

Column Origin Point - 1st Floor

Space Optimaztion

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Staircase - 1st Floor

Side Wall - 3rd Floor

Column Origin Point - 2md Floor

Column Origin Point - 2md Floor

Column Origin Point - 1st Floor

Column Origin Point - 1st Floor

Column Origin Point - 1st Floor

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08 ARCHITECTURAL DESIGN

[ Generation Logic ] The grids were applied to the architectural space. The overall space was selected according to the guide curve. The lines were generated by the shortest walk logic. Attract points are set at the middle of the column to find the best path between each floor.

After generation, lines were optimised according the spatial function. Staircase and walls were then designed to fulfill the space.

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Grid

Path

Optimized Lines

Staircase

Shortest Walk

Generated Lines

Wall

Final Space

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07 ARCHITECTURAL DESIGN [ Spacial Design | Component ]

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Facade

Column

Stairs

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07 ARCHITECTURAL DESIGN [ Section ]

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Fluid Deformation Research Cluster 5&6

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