BPro RC6 2014/15_SpaceStream

StreamSpace Design Portfolio

WonderLab :: Research Cluster 6, Daniel widrig, stefan bassing, Soomeen hahm Team Members:: Mengying LI, Zhen SHAN, Wenjian YANG, Shaoru WANG

CONTENTS 1 INTRODUCTION 1.1 Reference 1.2 Initial Attempts 1.3 Initial Set Up

2 MATERIAL AND FABRICATION 2.1 2.2 2.3 2.4

Material Tests Casting Study Straw Structure Development Chair Fabrication

3 Basic Design Language 3.1 3.2 3.3 3.4 3.5 3.6

Geometry Grid Lifting 2D to 3D Surface Inflation Bundle

4 Digital Design Tools

4.1 Lattice with Density 4.2 Bundle 4.3 Lattice Stigmergy

5 Material and Fabrication II 5.1 Grid Fabrication 5.2 Casting 5.3 Welding

6 Project Workflow 6.1 Digital Workflow 6.2 Physical Workflow

7 Design Application 7.1 7.2 7.3 7.4 7.5

Chair Design Column Design Staircase Design Pavilion Design House Design

Introduction Reference, Initial Attempts, Initial Set Up

1

RC6 CRAFTING SPACE

SPACESTREAM Mengying LI, Zhen SHAN, Wenjian YANG, Shaoru WANG

Starting with a brief introduction to the design project, SpaceStream is a project of Bartlett AD Research Cluster 6. Under Daniel Widrig’s guidance, the design project brings focus on the combination of traditional, hands-on crafting with advanced computational, technological tools to create or realize new construction methods and processes.

In fabrication research, it can be figured out that how the process and the method inspired from non-traditional materials are not utilized being a part of building but as the medium during the design process. Concretely, SpaceStream aims to explore a design system by using light weight materials and the method of casting to make a strong spatial structure.

Wax is initially introduced as a main role because of its character of flexibility and the traditional lost wax casting techniques. It is easy to be formed and lost in further casting process. Whereas on the other hand, the free form of wax is too difficult to control due to this kind of flexibility. Thus a wireframe system using straws is imported in to work together with wax.

Straws are used since it is easy to access and can be burned during the casting process. By dipping straw structure into melted wax, a thickness difference would be applied onto the straws. In the next stage, the combination of both straws and wax could be casted into a strong and controllable structure . Furthermore, before combining with wax, the straws system is also a great tool for small scale structural exploration. We

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have both basic structure research and design products made by straws.

In digital research, this project focus on demonstrating how Rule-based Digital Modeling affect crafting work in architectural design and the way it helps to increase working efficiency. Generally, there are five design language systems in SpaceStream project generated from straw studies. They are Geometry System, Grid System, Lifting 2D to 3D System, Surface System and Bundle System. All of them have certain principles of building up the language system, which are the bases for further digital modeling. To sum up, considering all the introductions above, the whole process of crafting work is very important as a premise to the following discussions about Rule-based Digital Modeling and a source which rules are extracted from. Correspondingly, based on the five systems, digital feedback can respond to and interact with crafting rule, in which way we could further improve existing crafting principles as well.

As an advanced version of Computer Aided Design, Rule-Based Digital Modeling has brought numerous opportunities to architectural design. It is affecting architectural design from all aspects, especially the tremendous contribution it made to enhance the efficiency of complex construction crafting working.

After getting feedback from digital modeling result, The new effects happened on simple materials but to affect the perception of space in new ways.

3

Concept

[ Reference ]

As most of inspiration in designers’ cognitive processes get from the environment surrounding people, and this porject is inspired from tradtional casting method- lost wax casting to study space frame from furniture scale to architecture scale.

2

1

1 Garment District Bart Hess 2013 2 Japanese Food Model 3 Metal Casting Dai & Ray 2008

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1

2

3

3

[ Introduction | References ]

5

4

5

6

4 Rupture Antony Gormley 2009 5 Steel Wire Sculptures Tomohiro Inaba 2003 6 Drift, lightweight structure Antony Gormley 2012

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[ Initial Attempts ]

In first fabrication research, we want to figure out that how the process and the method inspired from non-traditional materials such as straw, wax, and metal are utilized to affect design process.

Straws

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Wax

Metal

[ Introduction | Initial Attempts ]

Initial Material and Tool Testing -- Wax

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[ Initial Attempts ]

Initial Material and Tool Testing -- Straws

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[ Introduction | Initial Attempts ]

Initial Material and Tool Testing

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[ Initial Set Up ]

In this project, we want to figure out that how the process and the method inspired from traditional casting method is now utilized being a part of building but as the medium during the design process. In the initial set up, we take advantage of nontraditional materials to get a stable structure.

Straws are good materials as a tool to study linear structure system because of its low price, lightness and flexibility.

Wax is a common material used both in daily life and industrial manufacturing. It comes in several types which all have their own characters. Also, by the method of lost wax casting, it is easier to be converted into strong material.

Soda cans are made from aluminum which is a type of light metal and has lower melting point. Cans could be obtained from recycling and very common in daily life.

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[ Introduction | Initial Set Up ]

+

STRAWS

=

+

WAX

SODA CANS

METAL FRAME

In this project, some daily, simple, untraditional construction materials are utilized to make a spatial structure. By lost wax casting, straws, paraffin wax and soda cans are converted in to a strong metal structure system.

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12

Material and Fabrication Material Test, Casting Study, Straw Structure Development, Chair Fabrication

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[ Melting Point Test ]

Paraffin Wax 57-60°C

Beeswax 61-64°C

Paraffin Wax+ Beeswax To be tested

In the first material research, we would like to select a low melting point wax for later model making.

The testing result shows that by mixing two kinds of wax, the melting point of mixture will be between the two types of wax.

Paraffin Wax 58.4°C

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Beeswax 62.8°C

Mix 60.2°C

[ Material and Fabrication | Material Tests ]

[ Thickness Test ]

The purpose of this experiment is to test the thickness of 3 kind of wax under different temperature. The testing temperature is set according to melting points of each type.

After 10 times dipping, the thickness is measured by a vernier caliper.

Sample A Paraffin Wax test temperature 60°C 65°C 70°C

Sample B Beeswax test temperature 64°C 69°C 74°C

Sample C Microcrystalline Wax test temperature 71°C 76°C 81°C

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[ Thickness Test ] Wax samples

Low

Medium

High

Sample A Paraffin Wax

70°C

65°C

60°C

Sample B Beeswax

74°C

69°C

64°C

Sample C Microcrystalline Wax

81°C

76°C

71°C

Result diagram for Thickness Test of 3 types of wax

paraffin wax melting point

beeswax melting point

microcrystalline wax melting point

As can be seen from the testing result diagram, the wax layer gets thicker when approaching the melting point.

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[ Material and Fabrication | Material Tests ]

Wax just above melting point

First time dipping

Last time dipping

> Sample D Paraffin Wax temperature

61°C

(Melting point 57- 60°C )

dipping times

×10

smoothness

90%

> Sample E Beeswax temperature

65°C

(Melting point 61-64°C )

dipping times smoothness

×6 40%

> Sample F Microcrystalline Wax temperature

72°C

(Melting point 71°C )

dipping times smoothness

×6 30%

In the second thickness test, the 3 samples are designed to dip into paraffin wax, beeswax, microcrystalline wax which are at melting point temperature for 10times respectively. This test is set to see how the thickness changes after dipping several times.

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[ Conclusion ]

Therefore, comparing the characters of 3 different wax, Paraffin wax is the most suitable and preferable kind of wax to apply in the following researches.

Paraffin Wax

Microcrystalline Wax

Beeswax

57-60°C 61-64°C

Melting Point under interior temperature

71°C 1.096mm

Thickness under melting point

Smoothness under melting point

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1.104mm

1.660mm 90%

30%

40%

[ Material and Fabrication | Material Tests ]

Depend upon above researches, following conclusions could be drawn. > By mixing two types of wax, we cannot get a lower melting point of the mixture. > Thickness of the wax layer increases when approaching melting point. > The surface thickness of Paraffin wax is more average than Beeswax and Microcrystalline wax when getting close to their own melting points.

Therefore, comparing the characters of 3 different wax, Paraffin wax is the most suitable and preferable kind of wax to apply in the following researches.

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[ Wax Application Research ]

STEP 1

x8

Outer-inflate Surface Multiple Dipping Directions

Testing Structure STEP 1

Inner-inflate Surface Opposite + Multiple Dipping Directions

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[ Material and Fabrication | Material Tests ]

STEP 3

STEP 2

x(8+8) ROTATE x 4 times dipping

x8 (x 8 )+ (x 8)

x(8+8)

x(8+8) x8

x(8+8) x8

x8

x(8+8)

x(8+8)

STEP 3

STEP 2

x4 x8

x4 x8 (x 8 )+ (x 8)

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[ Metal Research ] Iron

Melting Point 1535

Price

√

√

Melting Point

x

x

hardness

√

√

Alloy

Melting Point 231 In this material research, price, melting point and hardness are the three main characters to be considered. After this research, aluminum is the suitable one for this

Price

x

x

Melting Point

√

√

hardness

x

x

x

x

√

√

project in this stage.

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[ Material and Fabrication | Material Tests ]

Steel

Aluminum

Melting Point 1515

Melting Point 660

√

√

√

Price

√

√

Price√

√

x

x

x

Melting Point

x

√

Melting Point√

√

√

√

√

hardness

√

√

hardness√

√

Cuprum

Silver

Melting Point 1083

x √

x

√

√

Price

√

√

√

Melting Point

√

√

√

hardness

√

Melting Point 962

x

Price x

x

√

Melting Point √

√

x

hardnessx

x

x

√

√

√

x

x

x

√

x

x

x

x

x

x

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[ Casting Study ]

STRAW

WAX

METAL Casting process Straw model to wax model Wax model to Metal Model

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[ Material and Fabrication | Casting Study ]

Wax Wrapping

Casting Silicono and Heat Gun

25

[ Straw Structure Development ]

initial physical studies of basic grid geometries

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[ Material and Fabrication | Straw Structure Devlopment ]

physical research from geometry to larger structure

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[ Straw Chair ]

Side View

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[ Material and Fabrication | Chair Fabrication ]

Front View

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[ Detachment ]

step 1

step 2

step 1

step 2

leg

leg

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[ Material and Fabrication | Chair Fabrication ]

Detaching the model into 5 parts to dip into wax.

For the base section, it was detached according to Mechanical laws. First, detachment changes all the bundle structure to be external part, which help to strengthen the bundle structure easily. At the same time, the inner straws of section could be stronger because the thickness of wax.

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[ Dipping into wax ]

Dipping the model into wax from different sides could help to control the thickness of wax according to different function. For example, it can be dipped from bottom to top for many times to strengthen the bundle structure of legs, and be dipped from to bottom to top for fewer times to make the seat lighter.

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1

2

3

4

5

6

[ Material and Fabrication | Chair Fabrication ]

7

8

1 dipping with the first part 2 dipping with the first part 3 after the first process 4 dipping with the second part 5 dipping with the second part 6 after the second process 7 straw prototype 8 half-wax prototype 9 wax prototype 9

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Side View

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[ Material and Fabrication | Chair Fabrication ]

Front View

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Side View

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[ Material and Fabrication | Chair Fabrication ]

Front View

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Basic Design Languages Geometry, Grid, Lifting 2D to 3D, Surface, Inflation, Bundles

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Basic Design Languages

[ Designs Based on Design Languages ]

In digital research, this project focus on demonstrating

how

Rule-based

Digital

Modeling affect crafting work in architectural design and the way it helps to increase working efficiency. Generally, there are five design language systems in SpaceStream project generated from straw studies. They are Geometry System, Grid System, Lifting 2D to 3D System, Surface System and Bundle System. All of them have certain principles of building up the language system, which are the bases for further digital modeling.

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[ Basic Design Language | Design List ]

GEOMETRY

GRID LIFTING 2D TO 3D SURFACE INFLATION

BUNDLES

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Geometry

[ Introduction ]

In this section, digital modeling is primarily based on the principles of such crafting work. Therefore, affecting by crafting resulit, geometry system is the starting point of whole digital system studies.

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[ Basic Design Language | Geometry ]

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[ Logics ]

TRIANGLES

basic geometry

2 groups

interlocking

3 groups

1st connection

2nd connection

4 groups

SQUARES

basic geometry

2 groups

interlocking

3 groups

1st connection

2nd connection

4 groups

PENTAGONS Initial digital logic research startsing from assembling different basic 2D geometries into groups. basic geometry

2 groups

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interlocking

3 groups

1st connection

4 groups

2nd connection

[ Basic Design Language | Geometry ]

TRIANGLES

SQUARES

PENTAGONS

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[ Process ]

step 1

step 2

x:0 y:0 z:0

step 3

x:0

y:0 z:0

x : 30 y : 0 z : 30

step 4

x:0

y:0 z:0

x : 30 y : 0 z : 30 x : 60 y : 0 z : 60

Among the three kinds of geometries, the structure made from triangles is chosen for its stability to design a seating object.

x:0 x : 30 x : 60 x : 90

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y:0 z:0 y : 0 z : 30 y : 0 z : 60 y : 0 z : 90

x:0 x : 30

y:0 z:0 y : 0 z : 30

x : 60 y : 0 z : 60 x : 90 y : 0 z : 90 x : 120 y : 0 z : 120

[ Basic Design Language | Geometry ]

Perspective View

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[ Physical Model ]

AGGREGATION

step 1

step 2

step 3 step 1

step 2

DIPPING INTO WAX

Since this structure doesn't have a clear boundary, a bigger scale model could be created separately and then binded together.

3rd section

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2nd section

Ist section

3rd section

2nd section

[ Basic Design Language | Geometry ]

step 3

Ist section

Perspective View

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Grid

[ Introduction ]

Considering the result from geometry system, design stracture must be stable during the casting process. Therefore, grid system is the improved geometry system using several same geometry connected by side.

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[ Basic Design Language | Grid ]

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[ Grid Study ]

In this page, the images show different attempts in grid study by changing scale and stype of geometry.

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[ Basic Design Language | Grid ]

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[ Gradually Change Study ]

scaling

basic grid

basic grid

new layer new layer

scaling

new layer new layer

In order to get stable and gradually changed grid, there are some results getting from scaling and transforming basic grid.

new layer

new layer

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transforming

transforming

[ Basic Design Language | Grid ]

Perspective View

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[ Subdivision Study ]

Component Generation

mirror 1

mirror 2

mirror 3

repeat 1

repeat 2

repeat 3

subdivision 1

subdivision 2

subdivision 3

This study tries to embody density by subdividing one type of basic geometry and combing them together in different directions.

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[ Basic Design Language | Grid ]

Perspective View

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[ Subdivision Study ]

Component Generation

basic geometry

new section

subdivision

new geometry

DEVELOPMENT

basic geometry

subdivision

Based on gradually change study, another attempt on subdivision study is realized by adding different types of geometries in grid system.

Using geometry’s internal subdivision embody the density of structure. new section

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new geometry

[ Basic Design Language | Grid ]

Perspective View

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[ Grid Connection Study ]

basic grid

Apart from subdivision, grid connection parts are one way to get strengthened structure.

Cause those part get thicker wax wrapped straw.

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developing

connecting

strengthening

[ Basic Design Language | Grid ]

Perspective View

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Lifting 2D to 3D

[ Introduction ]

At the same time, we also tried totally different design languages such as this, which is using a 2d pattern to create a 3d structure by lifting some of the vertexes.

es

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[ Basic Design Language | Lifting 2D to 3D ]

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[ Logics ] Perspective

at pattern

flat pattern

Top

strengthen main line

raise point and make it in 3D

lifting points to make it in 3D

strengthen the main line

add subsidiary lines

add subsidiary line

rendering

Top raise point and make it in 3D

Perspective

Perspective

strengthen main line

add subsidiary line

This diagram illustrates the process how to lift 2D pattern to 3D structure.

64

render

[ Basic Design Language | Lifting 2D to 3D ]

Top

ring

The prototype of 3D structure build by continual lines from 2D pattern

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[ Stool Design Logics ]

flat pattern

lift points

main lines

add subsidiary lines

seat

legs

Following the logic of the design language of Lifting 2D to 3D, we designed this stool shown on the right page. gradient grid

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pick outline

strengthen outline

add surface

[ Basic Design Language | Lifting 2D to 3D ]

Top View

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Perspective View In this stool design prototype, the continuous straws are more stable because of the girds. The grid acts as a support to the bundles and at the same time, thicker straws would also strengthen grid edges.

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[ Basic Design Language | Lifting 2D to 3D ]

Perspective View

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Surface

[ Introduction ]

Surface is another attempt of SpaceStream project. By using this method, the straws (linear elements) are used to to make surface - like strctures.

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[ Basic Design Language | Surface ]

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[ Component Generation ]

TRIANGLE

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

SQUARE

POLYGON

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[ Basic Design Language | Surface ]

2D pattern study including triangle, square, and pentagons as the initial study in surface research

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[ Development in 2D ]

TRIANGLE

SQUARE

POLYGON

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[ Basic Design Language | Surface ]

the process how to get surface prototype including different scale 2D patterns

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[ Development in 3D ]

top

front

perspective

top

front

SINGLE COMPONENT

MULTI- COMPONENTS

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flat pattern

flat pattern

bend 1

bend 1

bend 2

bend 2

aggregation

aggregation

perspective

[ Basic Design Language | Surface ]

After the study of plane pattern in 2D, we change the position of some point and get 3D component.

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Perspective View This page shows the rendering of a component design with the design language of surface.

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[ Basic Design Language | Surface ]

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Inflation

[ Introduction ]

The 5th design language is called inflation, it is based on the appearence of wax thickness. The inflation effect can be applied on the parts that need to be strengthened on the model.

According to the load analysis, parts that bear more are often located in the inner part of the model. Considering the dipping method of applying thickness, it is farely difficult the maker inner parts thicker than the outskirts.

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[ Basic Design Language | Inflation ]

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[ Outer Parts Inflation Study ]

outer parts inflation

(x 8 )+ (x 8) x8

Inflation more times dipping for outer parts

This is the method how you make the outer parts thicker. And those image on the right part show the different results controlled by dipping times ,divide position and outer parts position.

thicker at outer parts

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[ Basic Design Language | Inflation ]

model before inflation

inflation level 1

inflation level 2

inflation level 3

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[ Inner Parts Inflation Study ]

inner parts inflation

separat along the inflation edges

x4 each piece has its corresponding edges inflated

This is the method how you make inner part thicker. Dipping by pieces and connecting them after dipping can get inner part more thicker. assemble pieces

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[ Basic Design Language | Inflation ]

Perspective View

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Bundle

[ Introduction ]

To replace inflation system, we designed another system called the Bundles. Simplly duplicating the amount of edges at the same position, the bundle system could make certain edges of the grid looks thicker, which has the same effect with inflation system but no constrains from wax.

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[ Basic Design Language | Bundle ]

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[ Logics ]

the way how bundle system is applied onto the grid system

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[ Basic Design Language | Bundle ]

- long edges - one start point - more straws

- going along edges

- shorter edges - branching out - less straws - much thinner - more separated

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[ Logics ]

1 growing along the lattice 2 longer-thicker shorter- thinner 3 branch out when coming to shorter edges

lattice

90

thick bundles- long edge

more branches- less sticks- short edges

[ Basic Design Language | Bundle ]

Applying bundle system on half of the chair shows how the grid differs from the original one.

lattice only

bundles added

rendering

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[ Design Application ]

Top View

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Front View

[ Basic Design Language | Bundle ]

Perspective View The result of applying bundle system onto the lattice system. The two systems support each other to make a stronger structure.

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Digital Design Tools Lattice with Density, Bundle, Lattice Stigmergy

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[ Digital Design Tools ]

Based on all this six design languages, we also designed some corresponding digital design tools to achieve similar result of our design languages. There are 3 basic digital design tools in SpaceStream project. One is for generating gird with density difference, one is for bundles generation and the last one is for larger scale design proposal to set zones.

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[ Digital Design Tools | Catalogue ]

LATTICE WITH DENSITY

BUNDLES

LATTICE STIGMERGY

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Lattice with Density [ Space Packing System ]

Cuboctahedron To get a continuous and gradient grid, Cuboctahedron is chosen from polyhydron system to make a digital grid pile because it is a repetitive geometry which can form a bigger scale one with smaller scales ones.

cuboctahedron Reason 1

cuboctahedron cuboctahedron

octahedron cuboctahedron

cuboctahedron cuboctahedron

cuboctahedron cuboctahedron

cuboctahedron cuboctahedr

Reason 2

cuboctahedron

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cuboctahedron

[ Digital Design Tools | Lattice with Density ]

offsetting In terms of the subdivision rule to make a density difference, we chose to offset and linking the vertexes to achieve several levels of subdivision. In this way, each piece after cutting is a stable structure.

Reason 1

ron

Reason 2

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[ Basic Methods to Make Different Density Lattices ]

The diagram on the right shows the general rule of repalcement and subdivision -- having a pile regular geometry ready and replace them with different levels cutted pieces according to the attroctor or guide curve.

a cuboctahedron

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GEOMETRIES SUBDIVIDED IN DIFFERENT LEVELS

offseting 1/2 scale

REGULAR PACKED DEOMETRIES

subdividing into 15 pieces by connecting vertexes

REPLACEMENT IN DIFFERENT LOCATIONS

[ Digital Design Tools | Lattice with Density ]

[1]

[2]

[3]

[4]

[5]

[6]

Each piece of geometry is subdivided by offsetting and linking. And an attractor is set in a pile of regular grid, subdivide the neighbours.Then, as to the further subdivision, a smaller scale is placed in between and replace with smaller scale cut pieces.

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Bundle

[ Digital Workflow of Bundles ] [1]

lattice ready

[4]

Bundle Agents are imported to help create bundles aline the grid. Each point of agents draw trails when moving, after the whole movement , the trails are snapped onto its neighbour grid vertex. Then duplicate the trail to get bundles.

snapping trails onto the closest vertexs

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[ Digital Design Tools | Bundle ]

[2]

[3]

run agents with trails

[5]

agents stop

[6]

get the bundle route

duplicate along the route

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[ Subdivision and Bundle Systems ]

[1]

lattice 17x 9 x 3

[5]

This is an example for the whole process the first 2 digital tools. As you can be seen here, the agent movement is controled by flocking system and get similar results to the bun dle system principle. lattice 17x 9 x 3 lattice gradient

[9]

lattice 17x 9 x 3 agent amount = 25 x 3 separation = 50 9.9 cohesion = 55 0.5 alignment = 10 0.1 snapping = on

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[ Digital Design Tools | Bundle ]

[2]

[3]

lattice 17x 9 x 3 color guide curve: sundivision grey guide curve: bigger scale lattice

lattice 17x 9 x 3 subdivision

[6]

[7]

lattice 17x 9 x 3 agent amount = 25 x 3 separation = 30 1.0 cohesion = 80 3.4 alignment = 39 0.5 snapping = off

[4]

lattice 17x 9 x 3 selection

[8]

lattice 17x 9 x 3 agent amount = 25 x 3 separation = 39 4.8 cohesion = 69 2.2 alignment = 27 0.3 snapping = off

[10]

[11]

bundling

rendering

lattice 17x 9 x 3 agent amount = 25 x 3 separation = 50 9.9 cohesion = 55 0.5 alignment = 10 0.1 snapping = off

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Division of Innovative Research Toshiyuki NAKAGAK 2010

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[ Digital Design Tools | Lattice Stigmergy ]

[ Lattice Stigmergy ]

DiffuseRate = 0.5 minAge = 1 maxAge = 5 SelectionRadius = 0.189 Frame 1

DiffuseRate = 0.5 minAge = 1 maxAge = 5 SelectionRadius = 0.189 Framae 5

DiffuseRate = 0.5 minAge = 1 maxAge = 5 SelectionRadius = 0.189 Frame 12

DiffuseRate = 0.5 minAge = 1 maxAge = 5 SelectionRadius = 0.189 SelctionDone

DiffuseRate = 0.5 minAge = 1 maxAge = 5 SelectionRadius = 0.189 Frame 5 BakeDone

DiffuseRate = 0.5 minAge = 1 maxAge = 5 SelectionRadius = 0.189 Frame 12 ExtractGuideLines

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Material and Fabrication II Grid Fabrication, Casting, Welding

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Grid Fabrication

[ Grid Fabrication Methods ]

In fabrication process the straw structure research include 4 kinds of methods to build the basic geometry and assembling them together.

110

frame + straw

wax sticks

sticks

straws + joints

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[ Frames + Straws ]

2D

3D frame built by folding with 2D paper

112

[ Material and Fabrication II | Grid Fabrication ]

3D frame

113

[ Frames + Straws ]

Pic.1 - Pic.8 shows the process of how to use straw to build the basic frame.

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1

2

3

4

[ Material and Fabrication II | Grid Fabrication ]

5

6

7

8

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[ Wax Sticks ]

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[ Material and Fabrication II | Grid Fabrication ]

This is the process how to use solder gun to connect wax stick together with wood template help.

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[ Foam Sticks ]

x 6

detach the geometry into 6 suares

Cuboctahedron is made up of 6 squares, thus we follow the same principle to built a foam stick geometry by 6 squares.

118

[ Material and Fabrication II | Grid Fabrication ]

the prototype illustrating how to assemble basic geometry from one to double

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[ Straws + Joints ]

As there are 12 kinds of possible angle connection between each branch, a joint with 12 branches is designed. To cut off the branches that we don't really need, we cast the nod into wax.

Joint - Version 1

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[ Material and Fabrication II | Grid Fabrication ]

Joint - Version 2

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[ Wax Joints Casting ]

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[ Material and Fabrication II | Grid Fabrication ]

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[ Physical Model Fabrication ]

12- Branches Wax Joints

This page shows prepared wax joints and straw sticks in three different length.

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[ Material and Fabrication II | Grid Fabrication ]

25mm Straws

65mm Straws

145mm Straws

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[ Joining Process ]

These three images shows how to cut the branches that we don't need and how smooth surface can we get after cutting.

126

[ Material and Fabrication II | Grid Fabrication ]

This page shows the process of makeing structure with wax joints and different length of straws.

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[ Fabrication Process ]

square x 6 per geometry

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form a unit

units ready

assembling

[ Material and Fabrication II | Grid Fabrication ]

This is a photo of straw structure made from grid system and bundle system. A part of it would be later wrapped with wax and sent for casting in the casting foundry.

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Casting

[ Casting References ]

Reference: Foundry Casting

1 Foundry Casting 2 Melting Cans With the Mini Metal Foundry Grant Thompson 2014

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[ Material and Fabrication II | Casting ]

Reference: Grant Thompson Melting Cans With The Mini Metal Foundry2014 https://www.youtube.com/watch?v=lSoWxG30rb0

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Foundry Casting

[ Prototype Sent to Foundry ]

At this stage we took a part of the straw model and sent it to the foundary for casting.

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[ Material and Fabrication II | Casting ]

[ Process of Making Mould ]

The Crucible Foundry

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[ Process of Casting ]

The Crucible Foundry

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[ Material and Fabrication II | Casting ]

STRAWS

WAX

SILICON BRONZE

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DIY Casting

[ Getting Aluminum ]

Approximately 38-45 cans will yield 1 pound Aluminum

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In SpaceStream project, soda cans are collected from restaurants and parties.

X

√

[ Material and Fabrication II | Casting ]

4

5

3

6

2

7

1 8

1

cans

2 steel jar

3

4

handle

5

6

fire

concrete

charcoal

play sand

7 blower

plaster of paris

8

PVC pipe

steel bucket

steel pipe

bucket

tape 137

[ The Process of Making Casting Mould ]

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[ Material and Fabrication II | Casting ]

[ The Process of Burning Wax ]

temperature > 1000℃

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[ Oven Heating Analysis ]

temperature > 1000℃

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[ Material and Fabrication II | Casting ]

[ Casting ]

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[ DIY Casting Results ]

scraping the plaster mould

aluminum casting piece

[ Difficulties if Casting ]

unsafe

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high price

heavy

lack of equipment

[ Material and Fabrication II | Casting ]

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[ Brazing -- 2D ]

1 Piano Wires 2 2D Template -- squares and triangles 3 Brazing Preparation Work 4 Brazing Process 2

1

3

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4

[ Material and Fabrication II | Welding ]

[ Brazing -- 3D ]

1 Piano Triangles 2 3D Template 3 Brazing Process 4 Brazing Results 1

2

3

4

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[ Brazing -- Cubotahedron ]

Prototype This is a basic geometry of the wireframe system.

By welding all of them together, we can get the grid design language ready and in the next step, some bundles would be added onto the grid.

By assembling the basic geometries, we can get a space packing grid system.

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[ Material and Fabrication II | Welding ]

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Project Workflow Digital Workflow, Physical Workflow

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Digital Workflow

[ An Example of Digital Workflow ]

[1]

[2]

overall shape of a chair Digital Workflow

topology optimization and guide curve design

The 8 diagram shows the whole digital workflow of SpaceStream Project taking the chair design as an example. Based on the existing system, the design is mainly

[5]

[6]

controled by some guide curves.

We first have the design proposal ready, according to the topolgy optimisation tool, we designed some guid crvs, put them in a pile of geometries, subdivide and select the lines we want. Then use the agent running to apply the bundles selection

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adding large scale geometries

[ Project Workflow | Digital Workflow ]

[3]

[4]

importing guide curve in geometry piles

[7]

subdivision

[8]

adding extra supports

adding bundles

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[ An Example of Digital Workflow ] [1]

agent amount = 80 separation = 38 4.7 cohesion = 69 2.2 alignment = 27 0.3 snapping = off

[4]

Frames obtained from the bundle generation digital design tool shows clearly how the digital system follows the principle of bundle system.

By controling the parameters of flocking system, trails of agents are drawn and later snap onto the closest vertex of the grid.

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agent amount = 80 separation = 50 9.9 cohesion = 55 0.5 alignment = 10 0.1 snapping = on

[ Project Workflow | Digital Workflow ]

[2]

[3]

agent amount = 80 separation = 50 9.9 cohesion = 55 0.5 alignment = 10 0.1 snapping = off

agent amount = 80 separation = 50 9.9 cohesion = 55 0.5 alignment = 10 0.1 snapping = off

[5]

[6]

bundling

rendering

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[ Rendering ]

Top View

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[ Project Workflow | Digital Workflow ]

Perspective View

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Perspective View

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[ Project Workflow | Digital Workflow ]

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Physical Workflow

[ Detachment ]

B

C

A

A Front Section B Middle Section C Back Section D Bottom Section

D

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[ Project Workflow | Physical Workflow ]

1st level detachment

B

2nd level detachment

3rd level detachment

C

A

D

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[ Welding Tools ]

2

4 3

1

7

5

8 6

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[ Project Workflow | Physical Workflow ]

9

1 G clamp

6 iron wire in square

2 welding mask

7 TIG welding facilities

3 bolt cutters

8 leather gloves

4 angle grinder

9 Sketches

5 template

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[ Welding Process ]

TIG Welding

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[ Project Workflow | Physical Workflow ]

Welding with Templates The basic geometry used in SpaceStream Project is made of 6 squares or 8 triangles. A template is designed to hold these 2D patterns to help welding half of cuboctahedron. These half geometries are made for whole cuboctahedrons in the next stage.

Welding with Templates

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[ Welding Process ]

Detached Pieces Fabrication Process As each detached pieces of the chair is made based on the basic geometry -- cuboctahedron, it is easier to make them by removing edges from the geometry. Its relationship to cuboctahedron is also the bridge to comunicate with other welders who helped us in the initial fabrication process of SpaceStream.

Cuboctahedron Combination Welding

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[ Project Workflow | Physical Workflow ]

Cutting Extra Edges from Cuboctahedron

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[ Different Types of Detached Pieces ]

The detached pieces can be divided into 3 types which are pyramid - based pieces, 2D flat pieces and Cuboctahedron - Based Pieces. The overall shapes are different but they are all based on the Grid System and can be cut from a cuboctahedron.

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[ Project Workflow | Physical Workflow ]

Pyramid - Based Pieces

Flat Pieces

Cuboctahedron - Based Pieces

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[ Assembling into Bigger Scale Pieces ]

By assembling these detached pieces, some bigger second level scale grids could be obtained. This scale level is designed for adding bundles and in the last step these pieces will be assembled to finish the chair fabrication process.

1

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2

[ Project Workflow | Physical Workflow ]

3

4

5

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[ Assembling into Bigger Scale Pieces ]

By assembling these detached pieces, some bigger second level scale grids could be obtained. This scale level is designed for adding bundles and in the last step these pieces will be assembled to finish the chair fabrication process.

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[ Project Workflow | Physical Workflow ]

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[ the Fabrication of Bundle System ]

To make the physical bundles more continuous, a bending tool is designed and made according the space packing system. With this tool, it is easy to bend wire into sections in length of 4cm, 8cm and 16cm.

Bending Tool

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[ Project Workflow | Physical Workflow ]

manually aided bending by aluminunm tubes

bended wires

bundles on the grid

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[ Assembling ]

Having all pieces ready, the floowing step of the chair fabrication process is assembling. After this, some extra lines and thick bundles are added to finish all the fabrication process.

Bottom Section

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Middle Section

Front Section

[ Project Workflow | Digital Workflow ]

Sections Assembling

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[ Physical Model of Chair ]

Side View

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[ Project Workflow | Digital Workflow ]

Front View

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[ Physical Model of Chair ]

Chair Design model type : physical size: L 1400mm x H 800mm x W 900mm material : iron wires Ă˜ 3mm

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[ Project Workflow | Physical Workflow ]

Perspective View

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Design Application Chair Design, Column Deisgn, Staircase Design, Pavilion Design, House Design

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[ Inflation Design Process ]

importing guide curve in geometry piles

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selection and subdivision

[ Design Application | Chair Design ]

optimising

inflation

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[ Rendering of Inflation Design Furniture Pieces ]

Inflation Furniture Before the designof bundle system, some pieces of furniture have been designed based on the inflation system.

Although it is a different systems applied in the design, the principle of defining the location to be infalted is similar to bundling system.

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[ Design Application | Chair Design ]

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[ Subdivision and Bundling Design Process ]

importing guide curve in geometry piles

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selection and subdivision

[ Design Application | Chair Design ]

optimising

adding bundles

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[ Renderings of Subdivision and Bundling Designs ]

Bundle Application Furniture Before setting the principle of bundle system, several digital models which are applied with bundle are designed to expolre the rules and functional role of bundles

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[ Design Application | Chair Design ]

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[ Chair Rendering ]

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[ Design Application | Chair Design ]

Perspective View Among all the chair designs above, this inflation chair transfers the spirit of SpaceStream Project. It has gradually changing gird system and some part which needs to be strengthened inflated.

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Column Design

The column is designed as a bigger scale attempt than furniture. As the scale is larger, higher hierarchy in both gird and bundle systems are needed.

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[ Design Process ]

importing guide curve in geometry piles

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selection and subdivision

adding large scale geometries

[ Design Application | Column Design ]

adding bundles

adding extra bundles

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[ Design Process ]

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[1]

[2]

agent amount = 100 separation = 30 0.8 cohesion = 80 3.5 alignment = 40 0.5 snapping = off

agent amount = 100 separation = 32 1.5 cohesion = 78 3.0 alignment = 38 0.5 snapping = off

[5]

[6]

agent amount = 100 separation = 38 4.5 cohesion = 68 1.2 alignment = 28 0.3 snapping = off

agent amount = 100 separation = 40 5.6 cohesion = 65 0.5 alignment = 25 0.3 snapping = on

[ Design Application | Column Design ]

[3]

agent amount = 100 separation = 33 2.4 cohesion = 75 2.5 alignment = 35 0.4 snapping = off

[7]

bundling

[4]

agent amount = 100 separation = 35 3.4 cohesion = 72 1.8 alignment = 32 0.4 snapping = off

[8]

rendering

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Front View

198

Perspective View

[ Design Application | Column Design ]

Side View

199

Details

200

[ Design Application | Column Design ]

201

3D Printed Prototype This is a tiny scale prototype of the column design.

Left - Details of the Front View Right - Perspective View

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[ Design Application | Column Design ]

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[ Design Application | Column Design ]

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[ Details ]

3D Printed Prototype size: H 140mm x L 60mm x W 60mm material: SLS

206 206

[ Design Application | Column Design ]

207

Staircase Design

The staircase design is another attempt of larger scale design. As an architectural component, the staircase is at a similar scale but more complex than the column design because of its different levels of hierarchy in structure.

208

Details 209

[ Design Process ]

importing a main guide curve

optimising

210

[ Design Application | Staircase Design ]

importing second level guide curves

adding bundles for the center post

selection and subdivision

adding bundles for steps

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[ Design Process ]

guide curve generation

agent amount = 64 separation = 31 1.4 cohesion = 78 3.1 alignment = 38 0.5 snapping = off

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grid generation

agent amount = 64 separation = 34 2.7 cohesion = 74 2.3 alignment = 34 0.4 snapping = off

agent amount = 64 separation = 3 4.1 cohesion = 70 1.4 alignment = 30 0.4 snapping = off

[ Design Application | Staircase Design ]

agent amount = 25 separation = 30 0.8 cohesion = 80 3.5 alignment = 40 0.5 snapping = off

agent amount = 64 separation = 3 4.1 cohesion = 70 1.4 alignment = 30 0.4 snapping = on

agent amount = 25 separation = 30 0.8 cohesion = 80 3.5 alignment = 40 0.5 snapping = off

bundling

agent amount = 25 separation = 30 0.8 cohesion = 80 3.5 alignment = 40 0.5 snapping = on

rendering

213

Top View

214

[ Design Application | Staircase Design ]

215

Perspective View

216

[ Design Application | Staircase Design ]

217

Architectural Design

Architectural Design This section includes two architecture designs in different scales, a pavilion and a house. In this design process, the former design language needs to be developed to apply to more complex structures. For example, except the former design about vertical structru such as staircase and columns, the plane structure like wall roof and floor also need to be dissolved. Based on that, synthesizing different parts and creating a completed design system is the destination of the project.

218

219

220

[ Design Application | Architectural Design ]

Pavillion

221

222

[ Design Application | Architectural Design ]

Pavillion 223

[ Site Analysis ]

W118°48’36”

the United States

The site of the building is located in Los angles, on a slope of Solstice Canyon it is backed by mountains and face to a lowland, which give it a perfect view. A stream flow from the mountain and pass by the house. the flowing stream helps to decide the shape of the building and the tendency of the bundle.

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California

[ Design Application | Architectural Design ]

N34°03’18”

N34°02’42”

W118°47’24” N34°02’6” W118°46’12”

W118°45 N34°01’30”

Malibu, CA 90265, United States 225

N34°00’54”

Solstice Canyon

1

2

3

SITE

2 Woods 3 Waterfall

1 Vally

Water Green

Solstice Canyon 226

[ Design Application | Architectural Design ]

steam direction transportation site

227

[ Generation Process ]

Spatial Organisation

Design Proposal

Guide Curve

228

[ Design Application | Architectural Design ]

Grid Generation

Bundle System

House Design

229

[ Detachment ]

Column Origin Point --2nd Floor

Column Origin Point -- 1st Floor

Wall Origin Point -- 1st Floor

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Side Wall --2nd Floor

Architectural Design For the bid plane structure like floor or roof, a more effective method is separating them into several small parts to design respectively and patch together. This could improve the efficiency of both the design and fabrication.

Staircase --2nd Floor

Wall --2nd Floor

Side Wall --1st Floor

detachment zones

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[ Plan ]

A

A

1st Floor Plan 2

232

4

8

M

Roof Plan

2nd Floor Plan 2

4

8

M

233

[ Section and Elevation ]

A - A Section 2

234

4

8

M

[ Design Application | Architectural Design ]

Elevation 2

4

8

M

235

[ Rendering -- Detail ]

236

[ Design Application | Architectural Design ]

Cloumn

237

Spiral Staircase

238

[ Design Application | Architectural Design ]

239

Wall

240

[ Design Application | Architectural Design ]

241

Exterior Staircase

242

[ Design Application | Architectural Design ]

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[ Design Application | Architectural Design ]

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[ Design Application | Architectural Design ]

247

248

249

WonderLab :: Research Cluster 6, Dani Team Members:: Mengying LI, Zhen

250

iel widrig, stefan bassing, Soomeen hahm n SHAN, Wenjian YANG, Shaoru WANG