ARCHIPELAGO I DESIGN STUDIO MELBOURNE SCHOOL OF DESIGN UNIVERSITY OF MELBOURNE
ARCHITECTURE DESIGN THESIS
MARC MICUTA
SPECIAL THANKS TO OUR CRITICS, GUESTS AND SUPPORTERS
PROF. PHILLIP GOAD DR. KAREN BURNS
CHAIR. DONALD BATES PROF. ALAN PERT
DENNIS PRIOR BYRON KINNAIRD KIM JANG YUN JOHAN HERMIJANTO MICHAEL ONG THOMAS STANISTREET
KATIE CHECKEN CLARA FRIEDHOFF PATRICK HEGARTY ADILAH IKRAM SHAH JAYDEN KENNY STEPHANIE KITINGAN JANNETTE LE MARC MICUTA JACK PU
STUDIO LEADER: TOMMY JOO
contents
RESEARCH Additive + Distributed Manufacturing Deployable Structures Demountable Structures Future Practice References
DESIGN Program Joints Details Sections Plans Massing Project B Sketches
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67 69 79 89 95 101 109 119
thesis statement
The project was motivated by an interest in the possibilities for innovation in architectural design and practice enabled by the advent of a networked, distributed and additive manufacturing and construction industry. The design development focused on the iterative design of a series of joints intended to be fabricated using automated and additive manufacturing technologies. Parallel research focused on the future role of the architect and how the exchange between design practice, industrial manufacturing and academic research could be brought closer together under a single architectural program. The final architectural outcomes explored themes of on site manufacturing, mass customisation, recyclable building systems, demountable building systems and utilising both subtractive and additive manufacturing in a structural, aesthetic and tectonic language comparable to today’s standards of design and construction.
research
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ADDITIVE + DISTRIBUTED MANUFACTURING
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3D Printed Textile by Janne Kyttanen (2000)
Additive manufacturing, also known as 3d printing, is an automated manufacturing technology developed in the 1980s that consists of fabricating elements from the deposition of fine layers of material. Initially used for rapid prototyping of complex mechanical components, additive manufacturing started to be used to produce industrial design products around the year 2000. Affordable desktop Fused Deposition Modelling printers such as the MakerBot and RepRap series are playing a part in building up an advanced additive and distributed manufacturing industry, similar to the growth of the home computing industry in the 1970s and 1980s.
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Prusa Mendel (RepRap) 3D Printer
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US Patent for original Fused Deposition Modelling (FDM) Technology (1989)
Key patents controlling the licensed production of the main additive manufacturing technologies have either lapsed or about to elapse in the coming years. With technologies such as Fused Deposition Modelling (FDM), this has seen the explosive growth of additive manufacturing across numerous industries. The upcoming lapsing of patents for Selective Laser Sintering (SLS) and Photovoltaic Stereolithography should increasingly promote the additive manufacturing from a much wider variety of materials.
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US Patent for original Stereolithography technology (1984)
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Various publications discussing the future of advanced, automated, distributed and additive manufacturing methods
“It’s a paradigmatic shift in what manufacturing is going to look like. Historically, you think of manufacturing as an assembly line with thousands of workers and benefits. But here we are talking about very small batches, made close to consumers, and customised.” Ricardo Hausmann Director of Harvard’s Centre for International Development & Ex-Planning Minister for Venezuela
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Additive manufacturing and the associated transition to a distributed manufacturing industry is no longer speculative. Governments and Institutions are actively preparing to adapt to such changes, and have published reporting to explain how to prepare for the anticipated transition. During the last Australian Federal election cycle the topic of manufacturing was quite important. Advanced manufacturing technologies such as additive manufacturing will enable advanced economies with established and complex manufacturing infrastructure to more readily transition into a distributed manufacturing industry. Such an industry will have a much lower sensitivity to labour costs and will allow countries such as Australia, with high labour costs, to become competitive once again.
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Charles Hull patents Stereolithography.
Dr. Carl Deckard patents SLS. D-Shape unveiled
Stratasys launches first desktop 3D printer $4,995 S. Scott Crumb patents Fused Deposition Modeling. Launch of Rep Rap self replicating open source system.
1984 1989
2005 2007 2009 2011
2000
HISTORY Janne Kyttanen produces first AM lamp shade. $5,000
Shiro Studio collaborates with D-Shape Maufacture 3m high Radiolara pavilion.
Softkill Design propose a 3D printed house.
DUS Architects propose a 3D printed house. KamerMaker
TECHNOLOGY
Voxeljet launches VX4000.
D-Shape unveiled
launches first desktop 3D printer FDM achieved in Zero G on the ISS.
SLS Patent expires Formlabs launch Form 1
replicating open source system.
2011 2013
2016
2025
HISTORY
SPECULATION Titanium aircraft components manufactured by combining LDM with milling.
GE delivers first batch of GE9X Jet Engines. includes core AM components
Universe Architecture propose a 3D printed house.
Printed Artificial Bone Implanted Kyoto University Graduate School of Medicine
APPLICATION
Klein Bottle Opener - Stainless Steel (Bathsheba via Shapeways 2013) Opposite: D-Shape FDM Technology printing cementitious material
With current technology, most building materials used in the construction industry can be manufactured into components using additive manufacturing. The real barrier to adopting this technology for architectural design and construction is in the scale of the current stock of machines and the scale of the components they can output. Large scale specialist printers are becoming increasingly available.
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Titanium allow component for the Chinese J-15 fighter jet manufactured by combining additive manufacturing and milling technologies
Steel component manufactured with Laser Cusing additive technology
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Steel facade component manufactured with industry standard additive manufacturing technology
Structural components manufcatured from steel and titanium alloys are in current production utilising additive manufacturing. Aeronautical industries are demonstrating the most innovation in the production of these components, however projects such as the Nematox 2 above are distinct architectural applications of this technology.
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ProtoHouse by Softkill Design (2013)
Architectural applications of additive manufacturing that have gained taction in the media has been focused on the race to the first “3d printed house�. These speculative projects have been great to inspire imagination and to start a conversation, but my belief is that the first applications of additive manufacturing in the architecture and construction industries will be in a much more pragmatic and small scale manner.
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Canal House by DUS Architects and KamerMaker (2013)
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Landscape House by Universe Architects (2013)
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D-Shape large scale FDM printer (2010)
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VoxelJet VX4000 FDM particle printer with a build volume of 4000 x 2000 x 1000
The size, efficiency and ability of the additive manufacturing technology is converging from rapid prototyping to industrial production capacity. How can architects capitalise from such a transition to reduce time and cost in design and construction while maximising quality?
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The first design experiment I undertook this semester developed from an interest in how the nodes or joints in a structural system might be produced through additive manufacturing. This first experiment demonstrated how a desktop FDM printer can be used to print custom joints with a precise socket diameter and unique joining angles. The linear elements were manually trimmed from initially uniform skewers, representative of what could be achieved with an automated and subtractive manufacturing method. This first experiment influenced and inspired the trajectory for the rest of the thesis project.
Distorted Tower - Exchange - Marc Micuta (2013)
deployable structures
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The Hoberman Sphere - Hoberman Associates
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After deciding to further explore the potential for structural joints to be fabricated through additive manufacturing technology, my interests led into an exploration of deployable structures. Deployable structures required a complex moveable joint in order to allow the longer linear elements to fold and unfold in a manner similar to scissors. The Hoberman Sphere, the most prominent and recognisable deployable structure, utilised a scissor joint to fold the linear elements in two to more densely collapse the structure.
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Rolling Bridge by Thomas Heatherwick (2004)
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Thomas Heatherwick’s rolling bridge is an architectural demonstration of a deployable structure. I was curious whether the complex mechanical joints utilised in this structure could be customised at unique joint angles to assemble a distorted deployable structure.
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Deployable Structure by Dave Eaton
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Zipizip by Rodrigo García González
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Deployable Tower - Exchange - Marc Micuta (2013)
The second design experiment undertaken at the start of the semester aimed to design and fabricate a deployable joint and structure utilising the same equipment as the first experiment. The intention was to further develop this into a usable joint for the final project. However, the scale at which the elements are printed efficiently lacks the precision, resolution and size created numerous challenges.
demountable structures
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Jean Prouve - Demountable Bungalow
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Demountable structures such as the prefabricated bungalow by Jean Prouve have never seen a successful addoption rate. This is primarily believed to be due to the inabiiity for architecture produced through mass production to be suitably site responsive. With the speculative transition from mass production to mass customisation, it becomes possible to develop parametric designs that are able to respond to complex site requirements which maintaining elements of mass production enabled through additive manufacturing. This realisation formed the basis for Project B for the rest of the semester.
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FUTURE PRACTICE
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The Future For Architects? report released by RIBA in 2011 identified challenges to be faced up until 2025 for role of architect. The report suggests that small firms (sole practictioners), specialists and “starchitects� should remain relatively stable. The practices identified as being at greatest threat are medium sized design led practices and small boutique practices. One of the important suggestions for the evolving role of the architect is to further integrate academic research and education into architectural practice and to broaden the basic scope of services offered into other areas of business consulting. This assists to supplement a practitioners’ income through teaching but more importantly opens up doors for networking and for participation in a wider scope of work and in developing new approaches.
The Future for Architects - RIBA (2011) 57
Architectural Practice pre-1980s
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Architectural Practice 2013 (Lyons Architects)
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PRESENT
CONCEPT DESIGN DESIGN DEVELOPMENT REGULATORY REQUIREMENTS CONSTRUCTION DOCUMENTATION CONTRACTOR SELECTION CONTRACT ADMINISTRATION
DISRUPTION AND CHANGE IN ROLE
RAPID PROTOTYPING BRINGS DESIGNER CLOSER TO THE FINISHED PRODU
ITERATE BETWEEN CONCEPT AND BUILT DESIGN DURING DESIGN PROCESS
OPEN DOOR TO CUSTOMISATION AND SPREADING RISK OF DESIGN DEVELO
FUTURE
? INCREASED EFFICIENCY ? INCREASED EFFICIENCY ? FASTER + MORE PRECISE BUILD
NISHED PRODUCT - NO LONGER THE NEED FOR A BUILDER / INTERPRETER
SIGN PROCESS
DESIGN DEVELOPMENT OVER SEVERAL COPIES OF A PRODUCT
references
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(2011). Trends in manufacturing to 2020. Future Manufacturing. I. I. Council. Canberra, Industry Innovation Council - Department of Innovation, Industry, Science and Research. 3ders. (2013). “China shows off world largest 3D printed titanium fighter component.” Retrieved 28/10/2013, from http://www.3ders.org/articles/20130529china-shows-off-world-largest-3d-printed-titanium-fighter-component.html. Agency, E. S. (2013). “Call For Media: Taking 3D Printing Into The Metal Age.” Retrieved 28/10/2013, from http://www.esa.int/For_Media/Press_Releases/Call_for_ Media_Taking_3D_printing_into_the_metal_age. America, L. I. o. (2012). “The History of Laser Additive Manufacturing.” Retrieved 28/10/2013, from http://www.lia.org/blog/2012/04/the-history-of-laser-additivemanufacturing/. Architecture, U. (2013). “Landscape House.” Retrieved 28/10/2013, from http:// www.universearchitecture.com/landscapehouse/. Associates, H. “Portfolio.” Retrieved 28/10/2013, from http://www.hoberman.com/ portfolio.php. Bathsheba. (2013). “Klein Bottle Opener.” Retrieved 28/10/2013, from http://www. shapeways.com/model/321931/klein-bottle-opener.html. Cheung, K. C., Gershenfeld, N. (2013). “Reversibly Assembled Cellular Composite Materials.” Science 341(6151): 1219-1221. Design, S. (2013). “ProtoHouse.” Retrieved 28/10/2013, from http://www. softkilldesign.berta.me/project/. Eaton, D. “Deployable Structures.” Retrieved 28/10/2013, from http://daveaton. com/Deployable-Structures. Fitzgerald, M. (2013). “An Internet for Manufacturing.” MIT Technology Review 116(2): 71-72. 64
González, R. G. “Zipizip.” Retrieved 28/10/2013, from http://cargocollective.com/ zipizip/08. Hajkowicz, S., Cook, H., Littleboy, A. (2012). Our future world: Global megatrends that will change the way we live. CSIRO. Australia, CSIRO. KamerMaker. (2013). “Up up up!” Retrieved 28/10/2013, from http://www. kamermaker.com/?p=972. Kyttanen, J. (2013). “Janne Kyttanen.” Retrieved 28/10/2013, from http://www. jannekyttanen.com/. Laser, C. (2013). “Materials.” Retrieved 28/10/2013, from http://www.conceptlaser.de/en/technology/materials.html. Regalado, A. (2013). “The Next Wave of Manufacturing.” MIT Technology Review 116(2): 67-68. Regalado, A. (2013). “You Must Make the New Machines.” MIT Technology Review 116(2): 69-70. Rohrbacher, F. a. (2013). “AtFAB.” Retrieved 28/10/2013, from http://www.filsonrohrbacher.com/atfab.html. Shipp, S. S., Gupta, N., Lal, B., Scott, J. A., Weber, C. L., Finnin, M. S., Blake, M., Newsome, S., Thomas, S. (2012). Emerging Global Trends in Advanced Manufacturing. I. f. D. Analyses. Virginia, Institute for Defence Analyses. UK, M. (2013). “D-Shape.” Retrieved 28/10/2013, from http://www.d-shape.com/. VoxelJet. (2013). “VoxelJet VX4000.” Retrieved 29/10/2013, from http://www. voxeljet.de/en/systems/vx4000/.
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design
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program
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DESIGN OFFICE
industrial manufacturing
FABRICATION + PROTOTYPING LABORATORY
research institution
The program for the fnial project focused on bringing design practice, industrial manufacturing and academic research closer together. Influenced by Bryan Lawson’s model of the design or creative process, the program was organsied around specific relationships. Examples of creative workplaces such as the Pixar, Google and Apple offices and campuses that focus on promoting engaging workspaces, methods to create accidental interactions and incidental team work were also researched.
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SCHOOL OF DESIGN + manufacturing
material + structural testing
SCHOOL OF DESIGN + manufacturing
research institution
DESIGN OFFICE
WHO?
WHO?
WHO?
INDIVIDUAL PRACTITIONERS (COOPERATIVE) SMALL PRACTICES
UNIVERSITY / GOVERNMENT EMPLOYED RESEARCHERS TECHNICIANS + SPECIALISTS
TEACHING + ADMINISTRATION STAFF STUDENTS
ROLES + OBJECTIVES
ROLES + OBJECTIVES
ROLES + OBJECTIVES
PRODUCT DEVELOPMENT (SKETCH DESIGN THROUGH TO PRODUCTION) DESIGN WITH PRODUCT (CUSTOM DESIGN) SALES + MARKETING CUSTOMER MANAGEMENT TEACHING + EXPERIMENTAL DESIGN
RESEARCH OUTPUT (ACADEMIC) TECHNICAL EVALUATION + FEEDBACK PRODUCT STANDARDISATION + CERTIFICATION MATERIAL + STRUCTURAL PERFORMANCE TESTING + REPORTING BUSINESS CONSULTING TEACHING + EXPERIMENTAL DESIGN COLLABORATION WITH INDUSTRY
LEARNING - TECHNICAL FOCUS LEARNING - DESIGN FOCUS LEARNING - ENTREPRENEURIAL FOCUS IDEAS GENERATION + TESTING LEARNING (CLASSROOM MODEL) LEARNING (DESIGN STUDIO MODEL)
FABRICATION + PROTOTYPING LABORATORY
industrial manufacturing
WHO?
WHO?
TECHNICIANS ROBOTS (A.I.)
TECHNICIANS MANUFACTURING STAFF ROBOTS (A.I.)
ROLES + OBJECTIVES
ROLES + OBJECTIVES
FABRICATION + PROTOTYPING TEACHING + EXPERIMENTAL DESIGN
PRODUCT MANUFACTURING PRODUCT ASSEMBLY PRODUCT ISSUE MANUFACTURING CONSULTING
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DESIGN OFFICE
industrial manufacturing
FABRICATION + PROTOTYPING LABORATORY
research institution
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SCHOOL OF DESIGN + manufacturing
DESIGN OFFICE
FABRICATION + PROTOTYPING LABORATORY
research institution
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SCHOOL OF DESIGN + manufacturing
DESIGN OFFICE
industrial manufacturing
research institution
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DESIGN OFFICE
industrial manufacturing
FABRICATION + PROTOTYPING LABORATORY
research institution
75
SCHOOL OF DESIGN + manufacturing
material + structural testing
DESIGN OFFICE
FABRICATION + PROTOTYPING LABORATORY
SCHOOL OF DESIGN + manufacturing
research institution
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joints
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Timber Construction - Exchange - Marc Micuta (2013)
Steel Construction - Exchange - Marc Micuta (2013)
Assembly Axonometric - Exchange - Marc Micuta (2013)
details
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Passageway Platform - Exchange - Marc Micuta (2013)
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Slab to Frame Connection - Internal Habitable Spaces - Exchange - Marc Micuta (2013)
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Final Slab to Wall Details - Exchange - Marc Micuta (2013)
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sections
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Section Development - Exchange - Marc Micuta (2013)
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plans
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Floor Plan - Ground Level / Design Centrre - Exchange - Marc Micuta (2013)
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Floor Plan - Level 1 / Protoyping and Fabrication - Exchange - Marc Micuta (2013)
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Floor Plan - Level 2 / Representation and Reflection Space - Exchange - Marc Micuta (2013)
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MASSING
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Sketch Design 1 - Variable Grid Densities - Exchange - Marc Micuta (2013)
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Sketch Design 2 - Exchange - Marc Micuta (2013)
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Sketch Design 3 - Exchange - Marc Micuta (2013)
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Sketch Design 4 - Exchange - Marc Micuta (2013)
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Sketch Design 5 - Exchange - Marc Micuta (2013)
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project b sketches
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