BPro RC6 2015/16_ROPOLOGY

ROPOLOGY Research Cluster 6 Daniel widrig, stefan bassing, Soomeen hahm, Igor Pantic Jia-hao SYU, Aisha WANG, Lida ZHANG 05/07/2016

PROJECt Introduction Project ROPOLOGY aims to create self-supported rope structure by melting plastic rope. Instead of creating tensile structure, this project explores the potential of pressure resistance of plastic rope. The fabrication method of this project is layering continual ropes to make overlapping sinuous shape components which will then be slightly melted down to enhance the strength.

Based on the fabrication methods and material research, this project creates a loop system containing three design languages: local loop component, global loop bundle and global surface. After the components are set up, bundles and surfaces of different functions will be added to connect the components and strengthen the whole structure. By utilizing this system from small scale prototypes to furniture, the project will eventually attempt to achieve the designs of large-scale architectural elements.

CONTENTS CHAPTER 1 fabrication > REFERENCE > INITIAL MODELS > fabrication methods > MATERIAL RESEARCH

CHAPTER 2 DESIGN LANGUAGE > Geometry study > component language > connection language > aggregation logic > Strengthening language > Combination

CHAPTER 3 WORKFLOW > Digital workflow > Physical workflow > Application

CHAPTER 4 optimization > Shortest path > longuage transformation

CHAPTER 5 proposal > Aggregation I > Aggregation II

CHAPTER 1 fabrication > Reference > Initial models > Fabrication methods > Material research

PROJECT DESCRIPTION | REFERENCE

[ Crocheting & Stitching ] [ Rope is the perfect material for bio-morphic forms. By using crocheting techniques and repeating one stitch in a strict mathematical progression, rope can be transformed into a largescale and self-supporting scuplture. ]

1 1,2 3

Rope Scuplture by Judy Tadman Rope Scuplture by Heather Pickwell

2

3

[ Casting ] [ By using different hardening methods such as applying resin or melting polyrope, soft and lightweight rope can become strong enought to bear heavy load. ]

1 1 2

Knot Chair by Marcel Wanders Meltdown Chair by Tom Price

2

PROJECT DESCRIPTION | INITIAL MODELS

[ Fabrication ] [ Different fabriction methods were tried in the initial study, from weaving knots to layering ropes. In order to make the model self-suported, layering will be the main method. ]

weaving knots

spatial curves

Layering

PROJECT DESCRIPTION | Fabrication

[ Freeform ] [ Making freeform components aims to find some shapes and moments which can be simulated in the digital study. ]

model A

model B

model C

PROJECT DESCRIPTION | Fabrication

[ Template ] [ In order to make the fabrication process more precise, template is introduced to the fabrication set up. In this way, different components can be assembled together precisely. ] basic geometry

metal pipe

3D printed joint

+

combination

template A

component A

template B

component B

template C

component C

PROJECT DESCRIPTION | MATERIAL RESEARCH

[ Rope Samples ] [ Project ROPOLPGY aims to make self-supported rope models by melting them instead of applying hardening coating such as resin. Therefore several rope samples were tested in order to find the right ones which can be melted and easily shaped. ]

Rope 1

Rope 2

Rope 3

Material

Cotton

Synthetic Sisal

Polypropylene

Thickness

10mm

10mm

10mm

Hardness Shaping Melting point Price

180oC ~190oC

175oC ~180oC

Rope 4

Rope 5

Rope 6

Polyester

Polyester

Polyester

10mm

8mm

10mm

250oC ~260oC

170oC ~175oC

170oC ~175oC

PROJECT DESCRIPTION | MATERIAL RESEARCH

[ Thermal Test ] [ Heat gun was introduced to melt the rope. The rope will first be covered by tinfoil and held by metla wires to reduce the deformation during heating. Plaster was also applied on the surface of the model to keep the shape.]

COVERING MATERIAL

tinfoil

ORIGINAL

metal wire

HEAT GUN temperature range: 330oC & 560oC plaster

IGINAL MODEL

MELTED BY HEAT GUN

OUTCOME

The surface is harsh after melted by heat gun.

Plaster is heat-insulated which completely prevents the melting process.

Plaster is heat-insulated which completely prevents the melting process.

PROJECT DESCRIPTION | MATERIAL RESEARCH

[ Thermal Test ] [ After testing with heat gun, following the similar cover technique, rope samples were baked in oven which can provide evener heat. ]

COVERING MATERIAL

tinfoil

ORIGINAL

metal wire

sand OVEN temperature range: 90oC ~230oC

sand

&

plaster

mixture

IGINAL MODEL

BAKED IN OVEN

OUTCOME

The surface is smoother comparing with the one melted by heat gun.

The rope is completely melted down and messy since the sand is loose.

The rope is barely melted down after covered by mixture of plaster and sand.

PROJECT DESCRIPTION | MATERIAL RESEARCH

[ Thermal Test ] [ Several simple rope models were tested under different heating methods. This aimed to find the right temperature and casting method which can be applyed on the next step. ]

polyethylene rope

Before

A. heat gun

+

tinfoi

After B. oven

+

tinfoil

Casting Method

A

Sand: Plaster: Water C. oven

+ sand, plaster, water mixture

C 20 : 1 : 2

Time

10 mins

30 mins

Temperature

500oC

210oC

Hardness Deformation

C

B

C

C

20 : 1 : 2

30 mins

10 : 1 :1

1:0:0

30 mins

30 mins

30 mins

30 mins

220oC

210oC

230oC

220oC

PROJECT DESCRIPTION | MATERIAL RESEARCH

[ Thermal Test ] [ These images show the result of thermal test samples which were baked in oven. ]

synthetic sisal rope ( polyethylene )

Before

wrap with tinfoil After

baked in oven

Temperature

210oC

220oC

Time

20 mins

20 mins

Hardness Deformation

poly rope ( polypropylene )

230oC

210oC

220oC

230oC

20 mins

30 mins

30 mins

30 mins

PROJECT DESCRIPTION | MATERIAL RESEARCH

[ Thermal Test ] [ These images show the result of thermal test samples which were baked in kiln. ]

synthetic sisal rope ( polyethylene )

Before

wrap with tinfoil After

baked in kiln

Temperature

300oC

350oC

Time

30 mins

30 mins

Hardness Deformation

poly rope ( polypropylene )

350oC

350oC

350oC

400oC

40 mins

15 mins

20 mins

15 mins

PROJECT DESCRIPTION | MATERIAL RESEARCH

[ Hardness Test ] [ The less deformed thermal test samples are placed under the pressure of a 2kg object. It is noticed that several samples barely deformed under the pressure. The other samples also become harder while comparing with the original ones. ]

Sample

Before

After

Weight Deformation (under pressure)

2 kg

2 kg

2 kg

2 kg

2 kg

2 kg

PROJECT DESCRIPTION | MATERIAL RESEARCH

[ Deformation & Shrink ] [ The samples always deformed and shrinked significantly after heated, which is inevitable.

These images show the comparison between samples before and after heated. The blue dotted lines are the shapes of the original samples.]

Before

After

PROJECT DESCRIPTION | MATERIAL RESEARCH

[ Welding Ropes ] [ In order to avoid strong deformation, soldering gun is introduced. Soldering gun can be used in welding the ropes which can hardern the components to some extent. If stronger components are needed, they will be baked in oven in low temperature to avoid strong deformation. ]

thermal test

Sample

soldering gun welding

soldering gun welding + baked in oven

soldering gun

Harderness

welding ropes Weight Deformation (under pressure)

2 kg

2 kg

same components test

large components test

Before

soldering gun welding + baked in oven

After

soldering gun welding + baked in oven

PROJECT DESCRIPTION | MATERIAL RESEARCH

[ Prototype ] [ Series of components were welded by soldering gun. Components with high density are placed in the bottom part while those with less density are placed on the top. ]

top

bottom

prototype without bundles

PROJECT DESCRIPTION | MATERIAL RESEARCH

without bundles

with bundles

adding bundles

PHYSICAL TOOLS | TEMPLATES

[ Soldering Dot ] [ Instead of using glue gun as main tool for connectiong each rope surface, the soldering would be the alternative way to achieve the same goal. ]

Constraint points

+

PHYSICAL TOOLS | TEMPLATES

[ Bake Template ] [ In order to avoid deformation after baking in the oven, bake template is introduced to the baking set up. In this way, component could be hanged on the peak of the hook, which is use as constraint, while baking. ]

+

outcome

+ Temperature

220oC

Time

30 mins

Hardness

Deformation

PHYSICAL TOOLS | TEMPLATES

[ Heat Template ] [ In order to avoid deformation while heating, constraint template is introduced to the heating set up. In this way, component could be constrainted by the cone shape template. ]

metal sheet slide x 1 beam x1

+

+

outcome

Temperature

350oC

Time

20 mins

Hardness

Deformation

PHYSICAL TOOLS | TEMPLATES

[ Metal Template ] [ In order to avoid deformation when baking in the oven, metal template is introduced to the baking set up. In this way, component could be fixed while stucking in the each cylinder cones, which is use as constraint.]

M8 x 70mm Threaded Rod

M8 x 20mm Threaded Nut

115mm Aluminium Cylinder Cone

Three sides Steel Pyramid

[ Weld folded pyramid ]

3mm

The weld edges after folded

CHAPTER 2 design language > Geometry study > component language > connection language > aggregation logic > Strengthening language > Combination

DESIGN LANGUAGE | Geometry study

[ geometry selection ]

+

Triangular Pyramid

Rectangular Pyramid

C

Cube

Cuboctahedron

Icosahedron

DESIGN LANGUAGE | component language

[ Geometry-curve ] Control point curve

The following diagram tells the order of looping a singleline component with nurbe curve using the pyramid Wvertexes as control points.

triangular pyramid

control point

>

1

>

Process

2

3

>

1

1 loop

2 loop

3 loop

Result

DESIGN LANGUAGE | Geometry study

[ Geometry-curve ] Control point curve

rectangular pyramid

1 loop

2 loop

3 loop

Result

DESIGN LANGUAGE | Geometry study

[ Geometry aggregation ] Method i : Using adding strategy to find form.

assembling

adding

Method iI : Using CULLING SYSTEM to find form.

Guide curve

Culling geometry

DESIGN LANGUAGE | component language

[ logic ] Logic a Single line loop

Component a 2 rectangular pyramids

Component b 1 triangular pyramid+ 2 rectangular pyramids

Component c 2 triangular pyramids+ 1 rectangular pyramids

Logic b

Logic c

Logic d

Same size and density loop

Fullfilled loop

Logic a + Logic b

DESIGN LANGUAGE | component language

[ Local loop component catalog ] This page lists several possibilities of basic local loop components and mega local loop components with middle density.

Geometry a

Geometry b

Geometry c

Geometry d

DESIGN LANGUAGE | connection language

[ global bundle ] Method i : bundle Replacement according to the subdivision with the same organized form

Original size

Original size + Subdivided size

metthod ii bundle generating from seeds to Goal seeds with the different random form

Frame 1 Frame 1

Seed 1

Goal seed 1

Goal seed 2

Seed 2

Goal seed 2

Goal seed 1

seed 1

seed 2

Frame 2

DESIGN LANGUAGE | Aggregation logic

[ process decomposition ]

This diagram shows the process of two types of components connect to each others and aggregate with bundle layer added based on the frame.

+

2 types of basic components

Single-line component Offset by 4

rotate 1800

Combination

connection

DESIGN LANGUAGE | Aggregation logic

[ process decomposition ]

The following diagram shows the complexity of loop components based on twogeometry combinations, generating a type of ‘attachment’ in between basic components and bundles.

Global loop

Combination

Aggregation

DESIGN LANGUAGE | Aggregation logic

[ process decomposition ]

Original aggregation Small-scale Global loop

+

Large-scale Global loop

Final aggregation

DESIGN LANGUAGE | Strenghthening language

[ Surface ]

METHOD I : Fullfilled loop

Fullfilled loop components are strong surface based components made with high density loops.

Geometry a

Geometry b

Prototype a

Prototype b

DESIGN LANGUAGE | Strenghthening language

[ Surface Catalogue ]

METHOD II : Tween curve surface

Surface based components have the same idea with fullfilled loop of creating strong surfaces inside geometries to form structures in a whole systerm with more free style.

Geometry a

Prototype a

Prototype b

DESIGN LANGUAGE | Strenghthening language

[ Surface fabrication ]

original model

metal wire holding the gaps

metal sheet holding the shape

heated by heat gun

outcome

DESIGN LANGUAGE | combination

[ Loop + Surface ]

Prototype a

Prototype b

DESIGN LANGUAGE | combination

[ loop + global loop + Surface ]

Prototype a

Prototype b

CHAPTER 3 WORKFLOW > Digital workflow > Physical workflow > Application

WORKFLOW | DIGITAL workflow

[ chair analysis ]

Geometry a

Geometry b

+

Subdivision

This chair is made of the two types of basic pyramids triangular pyramid and rectangular pyramid.

A frame with hierarchy is designed firstly and components are input into each geometry according to the subdivision.

Two layers are generated inside this chair frame: Component layer and Bundle layer. Components have two sizes according to the frame while bundles are made to connect them as the structure.

bundle LAYER

+

+

middle-SIZE

+

component LAYER

+

SMALL-SIZE

WORKFLOW | DIGITAL workflow

[ chair analysis ]

Component list

Middle-size component

Small-size componentWW

Mega component

> Front view

> side view

WORKFLOW | DIGITAL workflow

[ chair catalog ]

These four chairs based on the loop logic and show the increasing density with different layers: small-size loop component layer, middle-size loop component layer, global loop layer and surface-based layer.

[ 1 layer ] > Global loop

[ 2 layers ] > Middle-size component > Global loop

[ 3 layers ] > Small-size component > Middle-size component > Global loop

[ 3 layers ] > Small-size component > Middle-size component > Surface

WORKFLOW | physical workflow

[ Fabrication ] The physical chair are made according to the aggregation logic with templates combining local loop components and global loop components.

This page shows the chair.

Back part

Seat part

Basic component

Component

assembling

WORKFLOW | Application

[ Stool assembing ]

Bundle layer

+

Component layer

WORKFLOW | Application

[ Stool strengthening ] Subdivsion_1

> middle-size component

Subdivsion_2

> middle-size component > small-size componen

WORKFLOW | Application

[ Bench ]

Large-size component

Small-size component

Global loop

Middle-size component

WORKFLOW | Application

[ Bench ]

WORKFLOW | Application

[ Bench ]

WORKFLOW | Application

[ Column ] Local loop component + Global bundle

Column a

Column b

Column c

WORKFLOW | Application

[ Assembling ]

Component

Global loop

Component

Global loop_1

Global loop_2

WORKFLOW | Application

[ Column ] Local loop component + Surface connection

Surface

Surface + Local loop component

WORKFLOW | Application

[ Surface ] Surface function : bench seat

WORKFLOW | Application

[ Surface ] Surface function : bench seat Connection between components

CHAPTER 4 OPTIMIZATION Pattern study language utilization

Optimization | Language utilization

[ Study of density ] Method i : Based on the density of each component

Grid 1 layer

2 layers

5 layers

9 layers

Method iI : Based on the scale of the component

Grid with subdivision

Size 1

Size 2

Optimization | LANGUAGE TRANSFORMATION

[ Language transformation ]

Local loop components

Glob

bal bundle

Surface

Optimization | LANGUAGE TRANSFORMATION

[ Language combination ]

Global bundle_3

Global bundle_2

Global bundle_1

Small-size component

Middle-size component

Optimization | LANGUAGE TRANSFORMATION

[ prototype ]

Ad

Prototype with density using same size of components

dd bundles

Using global bundles to connect different components

OPTIMIZATION | PATTERN STUDY

[

[ Pattern Study ] [ In order to find a proper form and pattern, this triel firstly scale the basic geometry up to architectural space, then cull pattern out from the component grid by using basic loop curve as guide curve. In meanwhile, the subdivision level of component is depends on the distance, the closer the component to the guide curve, the more dense it becomes.]

[

[ Geometry]

+ [ Cull pattern ]

+

=

[ Distance ]

[ Density ]

0

Unit: mm

200

OPTIMIZATION | PATTERN STUDY

[ Pattern Study ]

[

[ In order to find a proper form and pattern, this triel firstly scale the basic geometry up to architectural space, then cull pattern out from the component grid by using basic loop curve as guide curve. In meanwhile, the subdivision level of component is depends on the distance, the closer the component to the guide curve, the more dense it becomes.]

[

[ Cull pattern ]

[ Distance ]

[ Density ]

0

Unit: mm

200

CHAPTER 5 PROPOSAL Aggregation I Aggregation II

Proposal

[ Aggregation i ] Process

Guide curve

Subdivision_2

Form+Subdivision_1

Small-size component

Middle-size component

Local loop component +

Global bundle Global connection

Surface

Proposal

[ Aggregation i ]

Proposal

[ Aggregation ii ]

Process Load

extract

F2 F1

Proposal

Guide

culling g

+

Overall form

Guide

subdivis

e curve i:

geometry

insert

cull

+

e curve iI:

sion

12m x 18m X 6m grid

geometry aggregation

Proposal

[ Structure analysis ] load structure high density / two sizes of components

stair high density

fRame siZe: 500mm(side length)

Celin light / low density / large-size component

fLOOR 1 laid down on a hill connecting the stair

fRame siZe: 250mm(side length)

/ small-size component

Proposal

[ Bundle generating ]

80 COHESION

40 ALIGNMENT

30 SEPERATION

0.5 SEPERATION

1.0 COHESION

1.5 ALIGNMENT

Shortest Path

20 AGENTS

30 SEEDS

30 GOALSEEDS

Longest Path

4 AGENTS

3 SEEDS

3 GOALSEEDS

Proposal

Proposal

WORKFLOW | digital workflow