YES2021 - Senior Research Architecture Studio - 1/5 (Nahmad Vazquez)

BRING THE MACHINES. CREATE THE RULES. DESIGN THE SYSTEM

STUDIO

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Work produced by Senior Architecture Studio Studio 6 (Re) distributed machines

https://sapl.ucalgary.ca/

Copyright 2021 University of Calgary School of Architecture, Planning & Landscape All rights reserved.

No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage and retrieval system without permission in writing from the publisher.

Instagram: @ucalgarysapl Twitter: @ucalgarysapl

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{RE} Distributed

Machines

Dr Alicia Nahmad Vazquez THESIS:

REdistribution of design intelligence to the mind of the architect, the mind of the material, the mind of the machine and the mind of the inhabitant towards a new reality in which agencies are shared and authorship diluted. REdistribution through effective resource utilization.

PREMISE:

The studio through the mediums of architectural geometry and digital fabrication focus on proposing architecture in a speculative economy, creating new, augmented and sustainable models for people to live, work and play together. Architecture and its production are considered part of a larger ecological system that enables mass customization and distributed decision-making whilst optimizing resource utilization. At the core of the exploration lies the concept of participatory, democratized digital design and fabrication.

RE-distributed machines explores architectural geometries based on distributed digital production —the maturing technologies of robotic and digital manufacturing with their material conserving, ecologically, and structurally effective credentials are at the core of the design explorations.

The studio tasks can be described as: 1) assessment of resources; 2) design a kit of parts (design language); 3) Design the fabrication logistic and sequences; 4) develop a model for negotiated growth.

The tasks were developed exploring new modes of cyber-physical architecture, participatory resource allocation, that imagine positive use scenarios and a bright future for our built environments.

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SITE & TECHNOLOGY

Students during the term focused on engaging with mature digital fabrication technologies such as digital timber, robotic hot-wire cutting, abrasive wire cutting and 3D printing in clay and plastic as the basis to build upon and develop their projects. The short duration of the studio -3.5months- was a factor to avoid engaging with the complexities of material experimentation and directing the time and resources towards the study of spatial configurations, architectural geometry and the micro-fabrication facilities with its machines and sequences of operations.

{Re} Distributed Machines

STUDIO 6

The first part of the project consisting of the site analysis and evaluation of resources, was done as groups. Three remote locations suitable for each of the digital fabrication technologies were identified as sites that could benefit from an onsite micro-factory and have the resources necessary by the fabrication technology. By focusing on specific local means, and proposing an innovative spatial programme, the geometries and fabrication processes are customized to optimize resource utilization. Students analyzed resources, location and processing capabilities before settling to develop the program, geometries, and fabrication facility.

Studio deliverables and aims included developing a specific occupancy program, spatial configuration, construction kit of parts and the micro-factory that produces them, involving factory layout, machine inventory, sequencing of processes and final output.

The work presented in this book focuses on: Digital Timber in Hope Island 3D printing Clay and Plastic in Newfound Land Structural Ice and temporary structures in Inuvik

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STUDIO 6

{RE} Distributed

Machines _______________________________ Structure _______________________________

1. Digital Timber Hope Island

1.1 Jonathan Monfries Health + Education Facility 1.2 Faraz Shapourzadeh Hope Housing Complex 1.3 Seung Ho Rhee Hope Market place 1.4 John Baziuk The Roller Bay Resort 1.5 Hannah Mousek Research Station

2. Structural Ice Inuvik

2.1 Faezeh Yousefi Inuvik Accomodations 2.2 Yasmin Tajik Ice Maker Space 2.3 Rutvi Gajjar Inuvik Festival Market

3. 3D Printing NewFoundLand

3.1 Darryl Pollock Jellybean Project : Artist Residence 3.2 Andrew Burnyeat, Isabelle Jackson + Alexander Mayhew: The Jellybean Project 3.3 Andrew Burnyeat Accomodation Units + Main Lodge Facility 3.4 Alexander Mayhew Ocean Plastic Research Institute 3.5 Thomas Acheson Jellybean Project : AM Housing

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Hope Island Health + BLA BLA BLA Education Facility

Jonathan Monfries YOUR NAME OR TITLE

THE ISLAND SOLUTION The Hope Island Health + Education Facility represents a robust strategy to deploy a robotic fabrication system that utilizes local resources with the ultimate goal of attracting the island’s original residents who were wrongfully driven off the land. The Tlatlasikwala people have expressed an interest in re-occupying their island, and the economic strategy to support this has the opportunity to utilize deployable systems for construction of new buildings that will also utilize local resources.

This facility addresses the island need for a clinic and classrooms for children. By incorporating two institutional uses, the programming is able to better support the island within a singular contextual building footprint. The flexibility of the programming allows for expansion of either program should a new building replace one of the uses in the future.

The timber structure is designed as multiple meshes of curvilinear glulam beams that support a canopy bridging the two institutional uses to support the island. The resultant form is a fluid shell that exists contextually within the hillside landscape facing the ocean.

The structure is fabricated using a robotic fabrication micro facility that process the hemlock and pine lumber into laminations that are then assembled based on the strengths of each species. This results in glue-laminated beams with unique variations in layering based on the strengths required for the structure, as well as the ability to track wood quality, ensure precision, and reduce materials wastage. A kit of parts containing all nodes for the beams allows for straightforward assembly of the structure into a canopy system. This system is divided into a structural hierarchy based on a dual-mesh aggregation.

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canopy

health

nature

office

canopy

canopy

health

nature

p office

canopy

canopy

ealth

nature

classrooms

canopy

program within the landscape

office

classrooms

Integrated Program Strategies that have successfully integrated different programming elements with interstitial spaces that connect the program to nature (left page) and Hope Island proposal (right page). Precedents: Top - Puntukurnu Aboriginal Health Centre (Kaunitz Yeung Architects), Middle - New Shoots Children’s Centre (Collingridge + Smith Architects), Bottom - Solebad Saline Spa (Frei Otto).

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PU

BL

IC

PR

IVA TE

IVA TE

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UB

IC PU

BL

IC

IC

PR

IVA TE P

BL

PR

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Material from Local Resource A Hope Island application of utilizing local timber to create a high performance structural system. Local species are selected by strength and arranged into layers based on this strategy. The primary species used in order of strength are cedar (lowest), pine, and hemlock (highest).

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hemlock high-grade

longitudinal

hemlock low-grade

radial

hemlock medium-grade

tangential

Orthotropic axes of wood, adapted from Svilans (2021)1

RESOURCE AVAILABILITY

pine HIGH VERY

high-grade

pine medium-grade

pine high-grade

pine low-grade

Digital TImber. MicroFactory. Hope Island

hemlock medium-grade

HIGH highest grades of wood species are utilized at the outermost extent of lamination layers.

MEDIUM

PACIFIC OCEAN

BULL HARBOUR

Resource Availability Timber is abundant in the local area near Bull Harbour, the only village site on the island. This abundance of resources allows for a local manufacturing process that reduces transportation costs. The robotic fabrication micro-facility ensures the timber is processed efficiently and with minimal wastage.

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Assembly of laminations into a beam 1 (Hetzer, 1906)

Glue-laminated timber is layered with strongest species on the outsides.

2 (Swedish Wood, 2020)

Using splines and layering of laminations to create beams and joinery (Charleson, 2019)3

Timber Assembly Research The optimization of glulam timber fabrication on a remote island required the research of wood properties itself, as well as the assembly of lams into multiple layers based on strength.

The result is an application that is specific to Hope Island and informed by existing timber research.

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Photogrammetry of Timber (Bukauskas et al, 2019)

3m

Digital TImber. MicroFactory. Hope Island

Three primary axes of wood relative to growth direction (Svilans 2021).

5

6m

hemlock hemlock pine

1 2 3 4 5

Hetzer, O. (1906). Gluing of Planed Boards to Create Curved Beams.

Swedish Wood (2020) Science of Glue-laminated timber, www.swedishwood.com Charleson, F. (2019). London Euston - Fabricating a Forest. Bartlett School of Architecture.

Svilans, T. (2021). Integrated material practice in free-form timber structures.

Bukauskas, A, Mayencourt, P, Shepherd, P, Sharma, B, Mueller, C, Walker, P & Bregula, J (2019) Whole Timber Construction: A State of the Art Review, Construction and Building Materials, vol. 213, pp. 748-769.

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STRENGTH LOW

H H

STRENGTH HIGH

H H P P H H

STRENGTH MED

H H P

STRENGTH HIGH

H H P P H H Strengths of Laminations The creation of an inventory of beams with varying thicknesses allows for the arrangement of layers based on the demands for structural integrity. Hemlock, the stronger of the two species, is layered on the outside facing edges, where as pine is layered in the core of the beam. This strategy also creates a visual aesthetic where you can see the variation in species and texture based on their structural organization.

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arrangement and organization of wood species come together to create stronger, thicker beam

arrangement and organization of wood species come together to create stronger, thicker beam

ecies come together to beam

Material Studies Experiments with combining laminations from different timber species and testing their rate of flex. Provides a further understanding of how the layered laminations come together in certain areas where beams become thickest.

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LOCAL RESOURCE DEPLOYABLE SYSTEM MATERIALS EFFICIENCY

TRAN

On-site Fabrication The construction process capitalizes on existing ferry routes near the island, where shipping containers holding all the equipment needed to fabricate the structure are easily deployed and removed from site when complete.

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Micro Facility Local trees of hemlock and pine species are harvested traditionally to help employ residents. The logs come to the facility and are scanned for quality and determining best cut lines to prevent wastage. The dimensional lumber is moved down the line independently according to species, before they are united where lams are glued, clamped, and bent using a participatory process between robot arms.

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Node Aggregation The mesh structure is composed of an inventory of glulam beam nodes. The structure is split into a primary and secondary mesh system. The beams are bent into shape to create the catalogue of nodes that make up the canopy structure.

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open to below

H

open to below

open to above

outdoor terrace

open to above

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Hope Housing Complex

Faraz Shapourzadeh

Hope Island Housing Complex This graduate studio project explores the augmented agency of digital design and fabrication tools for the on-site construction of a housing complex located on a remote island (Hope Island, BC). As opposed to the traditional prefabrication modes of off-site construction with the environmental impacts and high costs of transportation and industrialization, a robotic micro-factory is designed for efficient adaptation to the non-standard conditions of the site and to optimize machine and resource utilization. Turning to the design side of the process, new robotic-driven design methods have actualized the mass customization of architectural elements based on the specific programmatic needs of residential spaces and new ways of programming the wood as the main local material resource. As a result, a space frame of bent wood nodes, beams, and panels have been proposed as the kit of parts being able to adapt to conditions like the program, site slope, orientation, fabrication constraints, etc.

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Lorem ipsum Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laboru. Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laboru. Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum

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Hope Market Place

Seung Ho Rhee

Hope Market Place The project is situated on Hope island in British Columbia which has relatively remote and hard physical accessibility into the island. The overall general objective of the project is revitalizing the local community by enhancing the local economy through providing a facility space for the main local industry, fishery, and merchandise market space for both residents and visitors.

Since the island the remote, micro factory on the site with machines is essential for producing the architectural parts for these facilities, from local natural resources, which is wood.

There are five programs embedded in the project: fish bidding space, fish retail markets and grocery markets for local residents and visitors, food court for dining and resting, and micro factory for fabrication of architectural parts.

As market complexes, Market hall in Rotterdam and Pike Place in Seattle were examined as program precedents. Like the central hall of the MVRDV’s markethall is connected to the outside square, the bidding space of the project is displaced in order to be connected to the harbour of the island, being arranged toward the harbour port for better fishery input transportation. Also, like precedents, food court of the project is separated from marketplaces by being arranged in different level. Different types of market stalls and furnitures were also examined with the precedents, resulting for the project to aim to set the fabrication process of parts that are not only for geometries of architectural components but also for embedded furnitures of the programs as well. A micro factory is arranged close to the forest on the back for better input access of material resource.

For material due to its high MOE value, three out of five main tree types in British Columbia are selected to be suitable as main resources for fabrication of the kit of bent parts.

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Objective

Revitalization of Local Communiuty

Merchandise for Reisidents&Visitors

Fishery Facility Space

Provide Customized Architectural Components

Provide Material Resource Micro Factory Local Trees

Site Timber Team BC Research Station

by Hannah Mousek

Hope Island

Roller Bay Resort

by John Baziuk

Health & Education Facility

by Jonathan Monfries

Housing Complex Hope Market Place

by Faraz Shapourzadeh

by Seung Ho Rhee

Harbour Port

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Program Precedents

Pike Place Market in Seattle

Market hall in Rotterdam

*http://www.capecentralhigh.com/tag/pike-street-market/

*https://www.mvrdv.nl

*https://www.pikeplacechowder.com/

Five Programs of Hope Market Place Lorem ipsum Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laboru. Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laboru. Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum

N

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Access to Forest (Masterial Resource)

Close to Local Residents

Facing Ocean/ Harbour Port Access of Fish Transportation

Digital TImber. MicroFactory. Hope Island

Spatial Arrangement of Programs

Table&Seats on 2nd Flr. Only for Dining

Types of Local Wood Resources

Suitable for Bending Laminated Timber

Ponderosa Pine

Red Cedar

Sitka Spruce

Western Hemlock

Douglas Fir

Height (m)

30

60

70

40

42-85

Diameter (m)

2

2.5

2

1 -1.5

1.5-2

MOE (Mpa)

9510

8270

11200

12300

13500 * naturallywood.com

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Overall Process

1. Digital Modeling & Calculation

2. Input of Local Wood Logs a

5. On-site Assembly & Construction

4. Customized Component Pa

Overall Process For the overall process, first it starts with digital modeling of designated geometry and finding the values for dimensions and bending path of component parts, using digital tools. These values are applied to the machine of the microfactory to transform local wood logs into designated customized kit of parts components. The fabricated parts are carried to the construction site and assembled and constructed on-site for final geometries.

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as Resource

3. Microfactory Fabrication

arts Products

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Why Micro Factory?

On-Site Wood Processing Using Local Resources Extreme Power (Heavy Lifting) Reduced Risk of Severe Casualties

Reduction of Cost in Some Mutiple Fields

Why Robotic/ Micro-Factory?

For overcoming the shortcomings of Hope island being remote from the mainland, microfactory plays very crucial roles. It allows local resource woods to be used and processed on the site. As robots are used, it can handle works with extreme power, accuracy and precision required its optimized movement and power.

Moreover, as robots replace humans, it reduces risk of severe casualties.

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Digital TImber. MicroFactory. Hope Island On-Site Fabrication Easy Access to Data from Remote Optimized Movements Accurate & Precise Positioning

Capability of Cuntomization

In addition, it overcomes of difficulties of phyiscal access by being remote, as data can be shared through internet world wide.

Therefore, the designer or program engineer does not physically have to be in the island. As result, it allows to reduce the costs of transportation of materials and labours with providing capability of customization.

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Kit of Parts Catalogue

Laminated Bent CLT Panels

Laminated Bent Glulam Beams

1

# of Parts:

Kit of Parts Kit of parts are largely divided into two categories; laminated bent CLT panels and laminated bend glulam beams. Each single element part can be used as an element of an assembled multi-consitute parts. This kit of parts provides parts with different bending, allowing to produce various curved geomtries. when they are assembled.

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Digital TImber. MicroFactory. Hope Island 2

3

4

For the purpose of carrying and being kept fabricated in micro factory, the maximum dimension of parts are restricted to 1X1X1 metre.

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Plane Ortho. Wall&Ceiling w/ Fenestration

Canopy / Shades

Slant Wall with Fenestration

Rail / Fence Type 1

Free Curved-Form Interior Wall

Rail / Fence Type2

Geometries of Assembled Parts (Architectural Elements) Various geometries of architectural components can be fabricated through assembly of the element form the catalogue, including typical plane walls and ceiling, slanted walls,. Interior walls with extra wooden strips for more dynamic curvatures, canopy with curved elements, and two different types rails.

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Double Stall Booth

Low Height Containment Stalls

Shevles

Stall for Light weighted Porducts

Canopy / Shades

Digital TImber. MicroFactory. Hope Island

Stall for Fish Bidding

Geometries of Assembled Components (Stalls/ Booth/ Shelves) Different types of market stalls can be produced from the kit of parts as well. Having different bending, dimensions and assembly of the parts are important for producing stalls with different purpose or functions. For bidding stall, it has to be low in height to be easlily seen and recognize the quantity. Some other stalls support only light-weighted items but provide better containment.

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Tables and Seat for Singles

Bar Tables & Stools

Tables and Seats for Double

Free Form Table w/ curved Strips Type1

Bench

Free Form Table w/ curved Strips Type2

Geometries of Assembled Components (Tables/Seats) Same logic applies for the seats and tables as well. Dimensions and curvature of these furniture determined by numerous factors including number of users, what they are eating. Therefore customized parts with different bending is crucial for fabricate optimized form for the optimized functions, and this can be reached through the fabrication in micro-factory.

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*facebook.com/watch/?v=782484718969760

Technology Precedent#1 (KUKA w/ Twig&Bot Bandsaw Endeffector)

For Dimensional Woods from Logs

Technology Precedent#2 (KUKA w/ Cutomized effector clamp head)

For Bent Laminated Beams

Technology Precedent#3 (Adapa Moulds)

*adapa.dk/

For Bent CLT Panel

*tts-group.co.uk

Digital TImber. MicroFactory. Hope Island

Technology Precedents

* vimeo.com/robotsinarchitecture

*materialdistrict.com

Technology Precedents for Fabrication Three different fabrication technology precedents are examined and utilized for the fabrication in the micro factory of the project; - Twig&Bot bandsaw w/ KUKA for cutting logs into dimensional wood - Another KUKA with cutomized endeffector by Sttutgart University for production of bent laminated wood beam - Adapa mould machines for bent concret panel can be also utilized for production of bent CLT Panel in the Project RE : DISTRIBUTED MACHINES

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Micro Factory Fabrication Process

1. Wood Processing (Macrocut)

2. Manual Woodshop (Microcut) / Glue Applying / D

5 Fabrication Procedures in Microfactory In the microfactory, there are five procedures for the fabrication of parts;

1. Wood processing for producing dimensional woods

2. Manual woodshop

3a. Fabrication of Bent Glulam

3b. Fabrication of Bent CLT Panel

4. Assembly of sigle parts for Muti-constitute parts.

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Drying

Digital TImber. MicroFactory. Hope Island

3b. Bending CLT Panel Fabrication

3a. Bending Laminated Glulam Beam Fabrication

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4. Assembly of Parts

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1. Wood Processing (Macrocut of Woods into Dimensional Strips)

Step 1. Wood Processing KUKA Robot with a large Twig&Bot Bandsaw endeffector transform a wood log into designated dimensional woods. Wood panels with designated thickness are produced from logs through cutting procedure by the KUKA robots with the bandsaw. Then these cut panels are rotated 90degree and be cut once again in a simlar way for production of wood strips with designated width and thickness.

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Digital TImber. MicroFactory. Hope Island

1-1. Cutting logs with programmed thickness to produce dimensional lumber panels.

1-2. Another run for cutting the dimensional wood panels with designated thickness

1-3. Dimensional wood strips are produced with designated width and thinkness.

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2. Manual Woodshop (Microcut) / Glue Applying / Moisture & Drying /

Step 2. Manual Woodshop Stations This is a manual woodshop stations for workers to manually select good wood strips from step1, do sanding micro/detailed cutting for more accuracy and details, and apply glue and moisture for the next procedure.

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Digital TImber. MicroFactory. Hope Island

Selection Station

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3a. Fabrication of Bent Laminated Glulam Beam

Step 3a. Fabrication of Bent Glulam Beam After applying mositure and glues, multiple wood strips are put together with one ends being stationary acnchored. Then starting from the another ends of compiled strips, a KUKA robot with customized clamp endeffoctor starts to put this strips and bend these strips together, following the programmed bending pathway. While one KUKA is bending them, the other KUKA robots put nails or scews to put compiled wood strips together.

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Digital TImber. MicroFactory. Hope Island

3a-1. Put multiple laminated wood strips and anchoring one end on a stationary anchor

3a-2. KUKA w/ clamp head bends assembled laminated strips together with follwing programmed pathway.

3a-3. The other KUKA put screw/nail to put strips together while bending.

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3b. Fabrication of Bent CLT Panel

Step 3b. Fabrication of Bent CLT Panel Bent CLT Panel are produced by KUKA with two Adapa mould machines. Wood strips from previous steps are stacked on one of the adapa mould machines. Then, the other adapa machine that is attatched to KUKA robot, is pushed down and put together in order to hold the strips. Cylinders of the both moulds moves together until they reach the designated programmed height for producing CLT panel with designated bending.

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Digital TImber. MicroFactory. Hope Island 3b-2. Cylinders of the both moulds move vertically until they achieve programmed and designated bending heights.

3b-3. Top mould machine is removed after bending and drying for production of bend panels.

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4. Assembly of Fabricated Parts for Multi-Constitute Parts

Step 4. Assembly Station After bent parts are produced from robots and machines from step3, they are manually put together and assembled by human to produce multi-constitute parts of the kit.

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Hope Market Place fabricated w/ Parts

Overall Fabrication of Market Place After parts are produced from the micro factory, they are carried to designated construction sites, and assembled and constructed together again for geometric production of architectural elements such as walls, ceiling, partitions, rails, and embedded funitures including stalls, shelves, tables, chairs, etc. as well.

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Hope Maket Place with Various Activities

South-east Elevation

Various Geometries of Market Place for Mulitple Programs By having kit of parts with various and customized bending, the project allows to achieve customized geometries of architecutral components and furnitures. resulting the project to have various programs to be embedded including different types of markets, fishery bidding facility, and dining and resting space.

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The Roller Bay Resort

John Baziuk

Project Overview The Roller Bay Resort stands as a new way of manufacturing a local renewable resource by using a robotic fabrication facility that sustainably harnesses and processes timber with the vision of growing the economy and bringing back the first inhabitance of Hope Island, British Columbia. The Resort’s programming includes a variety of oceanfront resort units, dining experiences, eco-learning centres, and is a surfing getaway. Its parametric design and robotic kit-of-parts customizations look to attract tourists and inspire future designers to implement the techniques it utilizes.

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The Return to Hope Island The local Indigenous population of Hope Island, British Columbia, is looking to rejuvenate their dwindling population. Access to the island is difficult, however it has an abundance of natural resources in timber. The Roller Bay Resort looks to take advantage of the island’s isolation and resources by deploying a micro-factory to build the Resort on-site. With the help of robotic fabrication, architecture can be designed and customized to suit the Resort’s inhabitants’ needs while also standing as a sustainable method when processing the resources.

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Digital TImber. MicroFactory. Hope Island

A Gap in The State-of-The-Art Timber and micro fabrication is a relatively new topic in today’s architectural industry, however gaps can already be found and extrapolated upon in order to create more sustainable methods of fabrication. This project challenges today’s current micro-factory delivery and functionality methods, other wood framing technologies, and using sawdust as a building material.

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All Terrain Micro Factory Deployment The All Terrain Micro Factory (A.T.M.F) would be first floated to the site on a tug and barge system. Once there, it will orientate itself on the site, begin gathering resources, and fabricate the first storage site for the 3D printed furniture. Once phase 2 is completed, the A.T.M.F. will continue to move across the site where the factory will consume, process and fabricate the wood resource into LVL systems, which will make up the unit’s structure. Once all is completed, the Final Phase would be for the A.T.M.F. to stop moving and continue fabricating any pieces that the Resort will need, such as different furniture, replacement LVL pieces, and surfboards.

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Continuous Framing Today’s typical wood building framing methods consist of cutting and nailing many pieces of dimensional lumber to create a building. Instead of cutting pieces of wood to fit a window in, the idea to bend the wood around the openings could be a more sustainable way to cut less and save more. This curved LVL system works by curving and wrapping its members around the structure without any significant cutting.

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3D Printed Furniture Currently, the wood fabrication industry has not found a use for all the sawdust it creates through processing wood. By collecting, adding adhesive, and extruding the sawdust as a filament with a robot, 3D printed furniture could be created on site for the Resort.

This method could help make the micro-factory industry even more sustainable by focusing on even the overlooked parts during fabrication.

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Lorem ipsum Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laboru. Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laboru. Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum

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Research Station

Hannah Mousek

Project Overview Working towards generating economic development on a remote island in British Columbia, the Hope Island Research Station considers local timber resources and re-distributed machines, proposing a new mode of digital fabrication. A kit-of-parts enables customization and facilitates the programs marine research and education goals.

Hope Island, home of the Tlatlasikwala First Nation, has been “working on creating economic opportunities so that the community can return to Hope Island to live and work”.* With the introduction of a number of programs, the project aims to work towards achieving these goals. The Hope Island Research Station works in concert with 4 other student projects to create the ingredients required to bring economic development to the community. The islands unique coastal setting and marine diversity makes it the perfect location for research and educational opportunities to take shape.

An onsite micro-facility is proposed as means of augmenting local resources and skills in order to produce innovative architectural outcomes. This new sustainable model of fabrication makes use of emerging robotic technologies with the hopes of offsetting the traditional unsustainable modes of mass production. The sites vast timber resources and remote location brings to light the need for a new model of design and production that focuses on resource utilization and on-site fabrication. * http://www.tlatlasikwala.com/

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HOPE ISLAND RESEARCH STATION

HOPE ISLAND

BY HANNAH MOUSEK

ROLLER BAY RESORT

BY JOHN BAZIUK

HEALTH & EDUCATION FACILITY

BY JONATHAN MONFRIES

HOUSING COMPLEX

BY FARAZ SHAPOURZADEH

HOPE MARKET PLACE

Digital TImber. MicroFactory. Hope Island

BC

BY SHAWN RHEE

LOCAL EMPLOYMENT

SITE INNOVATIVE LOCALIZED GEOMETRY

ON-SITE ROBOTIC FABRICATION

LOCAL TIMBER RESOURCES ECONOMIC OPPORTUNITIES

HOPE ISLAND RESEARCH STATION

RESEARCH STATION

BIOLOGICAL DIVERSITY

MACHINES

REMOTE LOCATION OF HOPE ISLAND

KIT-OF-PARTS

USERS

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Deploying on-site robotic fabrication techniques to create an architecturally innovative research station that responds to the sites needs and available resources.

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SITE OPPORTUNITIES

MARINE DIVERSITY

REMOTE LOCATION

“working on creating economic opportunities so that the community can return to Hope Island to live and work.”

COASTAL LOCATION

- Tlatlasikwala First Nation

JOB CREATION

RESEARCH/EDUCATION

LOCAL RESOURCES

DOUGLAS FIR

STRENGTH (Mpa)

STIFFNESS (MOE)

HARDNESS (N)

DENSITY (kg/m3)

SHRINKAGE

85

13440

3158

540

HIGH

54

8200

1470

339

LOW

81

12300

2740

429

HIGH

70

11030

2270

425

HIGH

structural lumber veneer plywood

WESTERN RED CEDAR 64% forested*

exterior lumber AGB (T/ 0 - 25

26 - 50 ha)

51 - 100 101 - 150 151 - 200 201 - 350 > 300

WESTERN HEMLOCK plywood framing

SITKA SPRUCE lumber furniture millwork

* Government of BC

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Digital TImber. MicroFactory. Hope Island

PROJECT GOALS

SUSTAINABLE FABRICATION

RESOURCE OPTIMIZATION

MARINE RESEARCH & EDUCATION

ECONOMIC RE-ACTIVATION

RE-DISTRIBUTION OF MACHINES

LOCAL RESOURCES

Data Collection

MICRO FABRICATION

Information Driven Design

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Local Knowledge and Skills

Winter 2021

KIT-OF-PARTS

Resource Driven Geometry

ARCH 702 83

COMMUNITY

EDUCATIONAL

ADMIN

ADMIN

RESEARCH

RESEARCH RECREATIONAL

COMMUNITY

EDUCATIONAL

RESEARCH

Deep Bay Marine Field Station The Deep Bay Marine Field Station on Vancouver Island done by Hemsworth Architecture was an interesting precedent to look at when considering the educational portion of marine research.

Operated by the Vancouver Island University, the program brings together marine research with educational opportunities all under one roof.

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SITE AWARE AGGREGATION

Digital TImber. MicroFactory. Hope Island

MULTIPLE ASSETS

Roatan Prospera Architecturally, Roatan Prospera by Zaha Hadid Architects, makes use of a kit-of-parts to generate customizable opportunities for users. Given the flexibility of onsite fabrication, customizable options were important to consider when putting together the Hope Island Research Centre. The site influenced aggregation of the geometry also inspired the project.

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INPUT

Research

Researcher

Community

Living

Living Unit Social Space Gym Lobby Sample Sorting Seawater W et L ab Dry Lab Marine Classroom Administration Multipurpose Space Demonstration Kitchen

Aggregation Taking into consideration site attributes such as wind, sun, and proximity to the ocean, the program aggregates itself on site.

Divided into 4 wings – research, researcher, community, and living – the program creates places more public areas for marine education and more private areas for research. A variety of structural frames come together with a kit-of-parts to create the final output.

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Digital TImber. MicroFactory. Hope Island

STRUCTURAL OUTPUT

KIT-OF-PART OUTPUT

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Hope Island Research Station The result is an output of structural components and parts that come together to make the Hope Island Research Station. A place where research and education come together to facilitate community engagement, marine prosperity, and economic development.

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Assets Adjust Based on Frame

Kit-of-parts A catalogue of parts, allowing for customization, was developed with the intent to be mixed and matched based on interior use.

Differing balconies, windows, stairs, roofs, walls, and furniture were created to accommodate the needs of the users. These components attach to a variety of frames, all of which adjust to meet the spatial needs of the users.

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STRUCTURAL DEVELOPMENT

FORM GENERATION FORM GENERATION

2 1

2

1

3

3

STRUCTURAL STRUCTURALCOMPONENTS COMPONENTS

4

4

JOINERY

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Digital TImber. MicroFactory. Hope Island

SECTIONAL VIEW

Single Living Unit

Sample Sorting

Social Space

Seawater Wet Lab

Multipurpose

Dry Lab

Classroom

Kitchen

SECTIONAL VIEW

Single Living Unit

Multipurpose

Administration

Marine Classroom

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LIVING UNIT

FRAME SIZE(S):

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Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore FRAMES: 2 aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi et dolore magna ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laboru. Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laboru. Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum

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RESEARCHER SOCIAL SPACE

FRAME SIZE(S): FRAMES: 2

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MULTIPURPOSE SPACE

FRAME SIZE(S):

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Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna FRAMES: 6+aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laboru. Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laboru. Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum

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RESEARCH LABRATORY

FRAME SIZE(S): FRAMES: 4

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Node Components

Fabrication Grain and nesting studies were conducted to determine the best way to fabricate the architectural geometry. Given the complexity of the nodes, it was determined that the most efficient path forward would be to cut the complex components from logs using a chainsaw then milling and do the more linear elements from smaller logs using a similar robotic method.

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Digital TImber. MicroFactory. Hope Island

NESTING STUDIES

ROBOTICALLY FEASIBLE

+

=

MINIMAL WASTE OPTIMAL GRAIN OUTCOME RESOURCE EFFICIENT

MICRO FABRICATION

5.

4.

5. Milling (Node Station) 6. Finishing 7. Storage 1. Resource Selection 2. Cutting & Transport

3. Scanning & Sorting

4. Rough Cutting 5. Band-Sawing (Beam/ Column Station)

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1. Resource Selection

2. Cutting & Transport

Cruisers survey the forest to locate the required timber for the project

Trees are felled by fallers and bucked to the required project dimensions then transported to a micro-factory

5. Milling (Node Station)

5. Band-Sawing (Beam/Column Station)

Rough node components are milled

Rough column/beam components are band-sawed

Micro-Fabrication Facility A micro-fabrication facility would process carefully selected logs from the area transforming them into a series of components using robotic fabrication methods and human labour.

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4. Rough Cutting

Logs are scanned, sorted, and sent to processing based on nesting studies

A robotically operated chainsaw cuts the logs into rough components

6. Finishing

7. Storage

Sanding and the milling joinery

Workers place final components in the storage facility

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Digital TImber. MicroFactory. Hope Island

3. Scanning & Sorting

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Inuvik Accommodations

Faezeh Yousefi

Inuvik Accommodations Seeking to revitalize a remote community in Northwest territories, Inuvik Temporary Accommodation aims to attract resources to the region by creating novel spatial experiences.

Utilizing on-site fabrication facility , this project intends to find architectural solutions by synthesising structural geometry with ice, which has historically been used as construction material by the indegionous people in the area. Utilizing ice as the primary material and a geometry that works in pure compression, reduces the need for multiple reinforcing materials because it forms a monolithic structure that behaves similarly to concrete.

The notion of an on-site microfactory will promote inclusion by allowing people to collaborate in design and fabrication while also addressing the issue of remoteness through the localization of materials and facilities.

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Structural Ice. MicroFactory. Inuvik

Temporary Accommodation

Micro Factory

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On-site Material

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https://www.inuvik.ca/en/index.aspdocs/fabricate-2020com/flux-vault-by-maurizio-barberio-giuseppe-fallacara/stereotomy-each-block-interlocks-with-the-adjoining-element/zine. com/design/buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

https://www.inuvik.ca/en/index.aspdocs/fabricate-2020com/flux-vault-by-maurizio-barberio-giuseppe-fallacara/stereotomy-each-block-interlocks-with-the-adjoining-element/zine.com/design/ buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

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Structural Ice. MicroFactory. Inuvik https://www.inuvik.ca/en/index.aspdocs/fabricate-2020com/flux-vault-by-maurizio-barberio-giuseppe-fallacara/stereotomy-each-block-interlocks-with-the-adjoining-element/zine.com/design/ buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

https://www.inuvik.ca/en/index.aspdocs/fabricate-2020com/flux-vault-by-maurizio-barberio-giuseppe-fallacara/stereotomy-each-block-interlocks-with-the-adjoining-element/zine.com/design/ buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

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SITE Inuvik, Northwest Territory, is the location of the site. Inuvik’s cold season lasts 4-6 months, with January being the coldest month. The structural Ice team proposed three separate programs with the intent of revitalization of the local economy and fostering inclusivity within this remote society by creating innovative solutions considering the natural and societal realities of this remote location. The focus of this project is on temporary accommodation.

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Structural Ice. MicroFactory. Inuvik RE : DISTRIBUTED MACHINES

Winter 2021

ARCH 702 107

https://issuu.com/roland771/docs/fabricate-2020com/flux-vault-by-maurizio-barberio-giuseppe-fallacara/stereotomy-each-block-interlocks-with-the-adjoining-element/zine.com/ design/buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

www.tripadvisor.co.ukcom/flux-vault-by-maurizio-barberio-giuseppe-fallacara/stereotomy-each-block-interlocks-with-the-adjoining-element/zine.com/design/buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

https://parametric-architecture.com/flux-vault-by-maurizio-barberio-giuseppe-fallacara/stereotomy-each-block-interlocks-with-the-adjoining-element/zine.com/design/buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

WHY A Micro factory ,supplied with on-site material, creates a novel spatial experience and, by attracting resources to the area, can revitalize the local economy.

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http://www.structural-ice.com/bridgeinice.htmlzine.com/design/buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

https://www.architectmagazine.com/design/buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

https://www.stone-ideas.com/65837/stereotomy-each-block-interlocks-with-the-adjoining-element/zine.com/design/buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

https://www.architectmagazine.com/design/buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

https://parametric-architecture.com/flux-vault-by-maurizio-barberio-giuseppe-fallacara/stereotomy-each-block-interlocks-with-the-adjoining-element/zine.com/design/buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

Structural Ice. MicroFactory. Inuvik

https://www.architectmagazine.com/design/buildings/the-making-of-mits-collier-memorial_ouk-england-london-43090849

HOW Combining digital fabrication with the geometrical logics of stereotomy , utilizing the local resources.

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Winter 2021

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https://www.archdaily.com/793287/bigyard-zanderroth-architekten?ad_medium=galleryuk-england-london-43090849

Baugruppe, Prenzlauerberg Baugruppe – German for “building group” – stands for a long tradition of self-initiated, community-oriented living and the shared responsibility of building which results in customized living solutions. Baugruppen is among the new models of housing that offer greater choice and lower costs, foster cohesive neighbourhoods.

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Structural Ice. MicroFactory. Inuvik https://www.bbc.com/news/uk-england-london-43090849

The Collective, London Co-living spaces at The Collective are designed on a foundation of continuous learning, innovation and improvement.

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Winter 2021

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Accommodation Typologies Six separate typologies were created, taking into account the number of users, their age, and their enthusiasm.

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Winter 2021

ARCH 702 113

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Winter 2021

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Winter 2021

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The Aggregation Aggregations are organised according to programs, with each cluster containing all of the developed typologies.

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Winter 2021

ARCH 702 119

Ruled faces extracted for wire-cutting

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Structural Ice. MicroFactory. Inuvik

Exploded Axonometric This diagram illustrates the segmentation of one typology, as well as the interlocking mechanism utilized for the joinery.

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Winter 2021

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The Micro Fabrication Facility The diagram illustrates all of the stages from material input to fabrication, and assembly, which were completed with the help of two robots, telehandlers, and workers.

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Winter 2021

ARCH 702 123

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Winter 2021

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Ice MakerSpace

Yasmin Tajik

Ice Makerspace Located on a remote location in the Northwest Territory of Canada, Ice Makerspace is a temporary facility made out of local material, ice and brings the opportunity of education on digital fabrication, innovation, and tool access to its users while making a profit. The users are a combination of hobbyists, laymen, and professionals. Design for a remote location makes the application of a microfactory even more practical and efficient so the design is a fabrication-aware form-finding. The principal digital fabrication technique that is used is abrasive wire cutting which is inspired by the art and science of Stereotomy, cutting three-dimensional solids into particular shapes. A specific fabrication set-up is designed to efficiently produce kits of part for assembly of the maker space. Taking advantage of the legacy mode, the micro-factory that is moved to the site by trailer stay in the site during the life of the makerspace and work as the robotic part of the maker space after fabrication and assembly of the building itself around it.

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Winter 2021

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Heinz Isler ice structures

Ice Formwork for Ultra

Da Vinci bridge, Arno Pronk

Steven Holl Architects

Studies Ice in Architecture is a great area of research that by implication of advanced digital technique has been developed. I categorized the main strategies of using ice in architecture in three categories: sprayed ice on fabric or inflatable structures, making formwork for producing high-performance concrete, structural ice.

This project is structural ice that is assembled by stacking kits of a part that are fabricated with robotic abrasive wire cutting and milling for joinery and connections.

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Abrasive Waterjet

Oscar Niemeyer, Alvorada Palace

Robotic Abrasive Saw

Structural Ice. MicroFactory. Inuvik

Diamond Robotic Wirecut Jelle Feringa & Wes McGee

Zaha Hadid Structural Ice

Gaudi Coulmn, Sagrada Familia

Robotic Wirecut applies a specific type of geometry to shapes known as ruled surfaces. In other words for the shapes to be wirecutable, they need to be ruled surface that’s the architecture language that was studied for this project.

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Winter 2021

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Makerspace Case Study Makerspace case studies are Autodesk, Artisans Asylum and Fablab Boston that are categorized into inovation, collaboration and universal education. Ice Makerspace is a educational and innovative one where hobyst, layman, professionals collaborate, use tools and get official and non-official education through making.

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Winter 2021

ARCH 702 131

Second Top FloorFloor (Education-Administration) 1 Classrooms 2

Computer lab

3

Gallery

4

Lounge

5

Offices

6

Kitchenet

2 1

Down Floor First Floor (Fabrication-Event)

1

Loading dock

2

Robatic - Microfactory Legacy mode

3

Storage

4

Material Receive

5

Event Space

6

Workshop

7

Waste Collection/Recycle – Stock Preparation

8

Rapid Prototyping

3 4

How the Space is Used?

With the style of a warehouse, a double-height space which is dedicated to event space is located in the center and the corresponding spaces are distributed around it. On top floor classrooms, kitchenette, administration offices, and on the ground floor, workshops, Robotics, Rapid Prototyping, Waste Collection and Recycling, loading dock, and storage are organized based on material circulation.

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2

3

1 5

4 6

2 3 4

1

8

5 7 6

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Winter 2021

ARCH 702 133

Material Re Waste Collection – Stock Preparation

Material Circulation

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ecieve Staging Area

Structural Ice. MicroFactory. Inuvik

Chamber3 Chamber2 Chamber1

Loading Dock

Legacy Mode Microfactory

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Winter 2021

ARCH 702 135

Microfactory and Kits of Parts The design of components and fabrication set-up was a back and forth process. The microfactory is equipped with two robots on track for abrasive wire cutting the shapes and milling for joineries. The stocks that need to be cut from all sides will be placed on a rotary table which is located at the end of the robot.

The overhead crane is equipped with a waterjet for pick and placement and stacking components.

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Structural Ice. MicroFactory. Inuvik Rotary Table

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Robots on Track

Winter 2021

Overhead Crane

ARCH 702 137

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Winter 2021

ARCH 702 139

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Winter 2021

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Winter 2021

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Inuvik Festival Market

Rutvi Vijay Gajjar

Inuvik Festival Market The aim of this project is to explore the new possibilities of ice and snow architecture in technology, function and artistic expression by designing and constructing a seasonal Market for the Inuvik Festival in the Inuvik region. So the market is designed and constructed with the collaboration of these three aspects which are ice architecture, micro factories and architecture geometry.

It includes the use of architectural geometry to study and divide spaces as well as make aesthetically pleasing and structurally strong units along with the understanding of the local material Ice. Micro-factories are placed on-site as they are versatile, highly automated with the support of artificial intelligence and robotics. This positively impacts the productivity, level of customization, cuts down on labor and transportation, ensuring cost savings.

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IA

MARKET

MF MICR O FA CT ORIES Technologically advanced manufactur ing setup,which has a wide range of process capabilities to achie ve mass customaiz ed end products.

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AG

Structural Ice. MicroFactory. Inuvik

ICE AR CHITECTURE

AR CHITECTURAL GEOMET RY Architecture is a domain that majo rly deals with geometry and visuals.Combination of applied geometry and architecture, to look at the design, analysis and manufacture processes .

Winter 2021

ARCH 702 145

Site Location The town of Inuvik is located in the northern west territories of canada, which is an extreme cold place. Hence Ice can be used as a local material.

The site is located near to the inuvik town adjacent to the Dempster Highway which is the only way to go to the northern terrorists. The site is surrounded with a lake and prairies on the other side.

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Structural Ice. MicroFactory. Inuvik MARKET

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Winter 2021

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Heinz Isler’s Ice Sculptures Isler developed his expertise in this rounded style of architecture by experimenting with ice structures. He would build the skeleton of a piece by hanging nets, balloons, strings, and cloth from trees, and then dousing the fabric with water. The creations strengthened as they froze over, and sometimes the original supports could be removed.

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Winter 2021

ARCH 702 149

Flemango Ice Tower The thin shell structure of 31 meters is made with an average thickness of 25 cm of fiber-reinforced ice sprayed on a huge inflatable. It is possible to build large thin shell structures by reinforcing ice by adding natural fibers such as wood fibers. These fibers make the ice much stronger and create a reliable building material.

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Structural Ice. MicroFactory. Inuvik

The Sagrada Familia The Sagrada Familia is designed by a model with suspended chains, which is better known as catenary design. A suspended chain or rope will always get the shape of a smooth curve, meaning that the chain is only subjected to tension and absolutely no pressure. An ice-composite (pykrete), a mixture of wooden fibers and plain ice, is used to give the ice three times more strength.

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Winter 2021

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Winter 2021

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Programm Precedents Take - Aways The major take aways from the programm precedents are of the arrangenment of the stalls, location of the gathering spaces and the types of stalls.

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Structural Ice. MicroFactory. Inuvik

Defining the Programm Festival Markets are usually open, but due to the extreme cold conditions, Inuvik Festival Market will be closed. The market consists of Artistits Stalls and Food Stalls to support the economy of the Town. The Market will become a place in the town for people to socialize and enjoy.

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Winter 2021

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Types of Artists Stalls in the Market

Open Self Stalls - Small Buisness Artists

Closed Stalls - Large Buisness Artists

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Structural Ice. MicroFactory. Inuvik

Types of Food Stalls in the Market

Open Self Stalls - Home Bakers

Closed Stalls - Local Food Vendors

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Winter 2021

ARCH 702 157

Site Grid As Inuvik is located in the extreme north of Canada, northern lights are sometimes seen in the southern direction as well. So for the site, I went with the hexagonal grid as it’s six sides reflects the six different surroundings of the site which includes the highway, the northern lights in the North and South, Lake on one side and the prairies on both sides

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Structural Ice. MicroFactory. Inuvik

Site Grid Deformation Imagining the market into clusters, the hexagonal grid is further deformed with two attractors which will behave as the centre of the different clusters and the centre part behaves as a passage.

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Winter 2021

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Market Aggregation The artists stalls and the food stalls are equally divided into the two clusters. The below part of the site adjacent to the lake can be used for the outdoors activities held during the festival. The stalls are arranged in a radial manner yet opening in different directions. This breaks the linearity of circulation, giving the customers a new experience of movement. through the market. The centre between the two clusters can be used for goods at night.

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Winter 2021

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Gathering Spaces During the day, the centre good passage can be used as a open gathering space with some outdoor furniture. The two attractors behave as the centre art pieces of the individual clusters.

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Winter 2021

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Primitive Layout Stalls + Geometry In accordance to the fabrication method and the program, a shell geometry is used which can be customised according to the different type of stalls and sizes.

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Winter 2021

ARCH 702 165

Spatial Catalogue Architecture Geometry The single stall geometries are combined into different clusters of two, three, four and five as per the market plan.

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Winter 2021

ARCH 702 167

Construction Sequence The shell structures will be made of fabric form work upon which water is sprayed.

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Winter 2021

ARCH 702 169

Micro-Factories For the construction system, different micro factories are build on the site.

1. The Wood Factory for Scaffoldings 2. The Steel Pipe Factory for Edge Beams

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Winter 2021

ARCH 702 171

Micro-Factories 3. The Fabric Factory for the Fabric Formwork

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Winter 2021

ARCH 702 173

Micro-Factories 4. Reinforced Ice Factory As the site is located next to the lake which freezes in the winter, the ice blocks from the lake are melted and mixed with the cellouse. This mixer is sprayed on the fabric form work through a movable robotic arm sprayer.

This factory will be moving with the robot car on the site.

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Winter 2021

ARCH 702 175

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Winter 2021

ARCH 702 177

Jellybean Project: Artist Residence

Darryl Pollock

Jellybean Project: Artist Residence The project explores customizability and ornamentation through a kit- of -parts approach within the processes of robotic additive manufacturing. Through micro factory deployment the site materials of ocean plastic pollution and the clayley landscape are harnessed to transform the remote area of British Harbour Newfoundland into a hub for ocean tourism, research, and the arts with new efficiencies and little environmental impact.

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3d Printing. MicroFactory. NewFoundLand USER RELATIONSHIPS

SITE MATERIALS + LOCATION

ST OM

RE

N

VIT AL

TIO IZA

IZA TIO

CU

N

MICRO-FACTORY

ENVIRONMENTAL IMPACT

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Winter 2021

ARCH 702 179

Ghost town

OCEAN PLASTIC RESEARCH

PLASTIC MICRO-FACTORY/ FAB-LAB

Robotics REVITALIZATION

HOUSING

FISHING RESIDENCE

ARTIST RESIDENCE

INSTITUTE

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3d Printing. MicroFactory. NewFoundLand

rethinking norms CONSTRUCTION INNOVATION

DFAB HOUSE BY NCCR

complexity “FREE DETAILING” RONALD RAEL

Kit - of - parts LEVERAGED THROUGH DIGITAL FABRICATION

TERRA PERFORMA BY IAAC

BRITISH HARBOR PREDOMINANTLY CLAY BASED

SOIL

MOST LITTERED BEACH FRONTS OCEAN PLASTIC RESEARCH ‘GHOST’ TOWNS

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Winter 2021

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clay

plastic

PRIMITIVE DESIGN

CATENARY VAULT

PRIMITIVE CHANGE AFTER STRUCTURAL ANALYSIS

PRIMARY STRESS LINES DELETION OF UNNECESSARY STRUCTURE

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3d Printing. MicroFactory. NewFoundLand

catenary

earthen

vault GEOMETRY INFORMS SPACES

STEP 1 - INPUT SITE MATERIAL STUDIES

DIGITAL FAB INFORMS GEOMETRY

STEP 3 - GEOMETRY STEP 2 - SPACE

STRUCTURE FROM STRESS

STEP 4 - DIGITAL FABRICATION

program studies PROGRAM PRECEDENT STRUCTURE VARIANTS

spatial studies CUSTOMIZATION

user needs

USER INPUT INFORMS CUSTOMIZATION

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Winter 2021

ARCH 702 183

REMOTE, SECLUDED MODERN OVER THE COASTLINE SMALL SCALE LOW SITE IMPACT ORIENTED FOR SUN AND VIEWS

FOGO ISLAND ARTIST STUDIOS BY TODD SAUNDERS

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Circularity via Effective Resource Utilisation

3d Printing. MicroFactory. NewFoundLand

ACCESS TO AMENITIES (LIBRARY, LOUNGE, EXHIBITION) ACCESS TO MATERIALS, MACHINES, FAB LAB WORKERS HOUSING ACCESS TO AMENITIES (FISHING LODGE, GEAR) ARTIST RESIDENCY TOURISM TO THE BAY

OCEAN PLASTIC RESEARCH INSTITUTE

PLASTIC MICRO-FACTORY/FAB-LAB

HOUSING

FISHING RESIDENCE

ARTIST RESIDENCE

The Banff Centre RE : DISTRIBUTED MACHINES

Winter 2021

ARCH 702 185

PHOTOGRAPHY

PAINTING

DIGITAL ART AND DESIGN

PAINTERS - JANE AND JOE

FILM PHOTOGRAPHER MAURY

GRAPHIC DESIGNER - CHARLOTTE AND SPOUSE

ROOM REQUIREMENTS:

ROOM REQUIREMENTS:

ROOM REQUIREMENTS:

- BRIGHT, EVEN LIGHT - GOOD VIEWS OF THE AREA - STORAGE - SPACIOUS

- LONG TABLES - LIGHT TIGHT DARKNESS - BASINS FOR WASHING - AREAS FOR HANGING PHOTOS - STORAGE

- BRIGHT - GOOD VIEWS - WORK TABLE - DESK - STORAGE

HOW CAN THESE SPACES DIFFER BASED ON USER NEEDS?

STUDIO

KITCHEN

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W/C

DINING

BED

LIVING

Circularity via Effective Resource Utilisation

AS FOUNDATIONAL PROCESS

TERRA PERFORMA BY IAAC

re-examine

environment

DFAB HOUSE BY NCCR

APIS COR

PROGRAMMING FOR DIGITAL FABRICATION

LESS DESTRUCTIVE PROCESSES

3d Printing. MicroFactory. NewFoundLand

customization

KIT OF PARTS

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Winter 2021

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EXAMPLE COMBINATIONS

+ + + + + +

+ + +

FILM PHOTOGRAPHER - MAURY ROOM REQUIREMENTS: - LONG TABLES - LIGHT TIGHT DARKNESS - BASINS FOR WASHING - AREAS FOR HANGING PHOTOS - STORAGE

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ROOM REQUIREMENTS: - BRIGHT, EVEN LIGHT - GOOD VIEWS OF THE AREA - STORAGE - SPACIOUS

3d Printing. MicroFactory. NewFoundLand

PAINTERS - JANE AND JOE

GRAPHIC DESIGNER - CHARLOTTE ROOM REQUIREMENTS: - BRIGHT - GOOD VIEWS - WORK TABLE - DESK - STORAGE

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Winter 2021

ARCH 702 189

SPATIAL UNITS AS VAULT VOXELS

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3d Printing. MicroFactory. NewFoundLand SELECTED SPATIAL AGGREGATION AS VOXEL AGGREGATION VAULT AGGREGATIONS ACCORDING TO VOXELS

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Winter 2021

ARCH 702 191

WALL CUSTOMIZABILITY BASED ON PROGRAMMATIC NEEDS

LIVING ROOM DINING PATIO STORAGE KITCHEN LOUNGE STUDIO BEDROOM BATHROOM

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Circularity via Effective Resource Utilisation

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3d Printing. MicroFactory. NewFoundLand

FURNITURE CUSTOMIZABILITY BASED ON PROGRAMMATIC NEEDS

Winter 2021

ARCH 702 193

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AS FOUNDATIONAL PROCESS

CLOUD AFFECTS + B515 STUDIOS

texture

environment

WAVE / CAVE BY SHOP ARCHITECTS

EARTHSCAPER BY RAEL SAN FRATELLO

ORNAMENTATION AND CUSTOMIZATION

3d Printing. MicroFactory. NewFoundLand

Mixed materials

NEW WAYS TO LEVERAGE RESOURCES

TRANSPARENT PLASTIC

CLAY TRANSPARENT PLASTIC

OPAQUE PLASTIC

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Winter 2021

ARCH 702 195

CLAY EXTRUSION

1 UNPACK

2 DEPLOY

4 CONTINUOUS EXTRUSION

5 KEYSTONE EXTRUSION

3 MATERIAL EXTRACTION

KEYSTONE INSTALL

SHIPPING CONTAINER 1 - 2 BOOM LIFTS - 2 HOSES FOR CLAY - ADDITIVES FOR CLAY - MISC CONSTRUCTION EQUIPMENT

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3d Printing. MicroFactory. NewFoundLand SHIPPING CONTAINER 2 - EXCAVATOR - CLAY PUMP - CLAY MIXER - GENERATOR - 2 ROBOTS - MISC CONSTUCTION EQUIPMENT

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SHIPPING CONTAINER 1 UNLOAD SEQUENCE 1 HOSES 2 WHEELBARROWS 3 ADDITIVES 4 BOOM LIFTS

4

3 1

2

SHIPPING CONTAINER 2 UNLOAD SEQUENCE 1 CLAY PUMP 2 GENERATOR 3 EXCAVATOR 4 MISC CONSTRUCTION EQUIPMENT 5 ROBOTS WITH BOOM LIFT 6 CLAY MIXER

5 4

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3d Printing. MicroFactory. NewFoundLand

SHIPPING CONTAINER 2 UNLOAD SEQUENCE 1 CLAY PUMP 2 GENERATOR 3 EXCAVATOR 4 MISC CONSTRUCTION EQUIPMENT 5 ROBOTS WITH BOOM LIFT 6 CLAY MIXER

3 2

1

SHIPPING CONTAINER 2 UNLOAD SEQUENCE 1 CLAY PUMP 2 GENERATOR 3 EXCAVATOR 4 MISC CONSTRUCTION EQUIPMENT 5 ROBOTS WITH BOOM LIFT 6 CLAY MIXER

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MATERIAL EXTRUSION 1 1 CLAY PUMP 2 PUMPING CLAY THROUGH HOSE TO ROBOTS 3 ROBOTIC EXTRUSION OF CLAY LEGS

1

2 3

2

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3d Printing. MicroFactory. NewFoundLand

MATERIAL EXTRACTION AND PREP 1 EXTRACTION OF CLAY FROM SITE 2 ADDITIVES TO CLAY 3 CLAY MIXING

1

MATERIAL EXTRUSION 2 - PRINT 4 LEGS OF VAULT

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MATERIAL EXTRUSION 3 - CONNECT THE LEGS WITH THE ARCHES WORKING FROM LEG INTO CENTRE OF ARCH

MATERIAL EXTRUSION 4 - EXTRUDE KEYSTONE PIECES ON THE GROUND

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3d Printing. MicroFactory. NewFoundLand LIFT INTO PLACE - LIFT AND INSTALL KEYSTONE PIECE WITH BOOM

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Winter 2021

ARCH 702 203

ORIGINAL VAULT PRIMITIVE SPLIT INTO COMPONENTS DUE TO ROBOTIC ARM EXTENTS

1400 MM

1860 MM

INTERLOCKING SLOTTED JOINT

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3d Printing. MicroFactory. NewFoundLand

50 MM

70 MM

70 MM

100 MM

100 MM

100 MM

INTERLOCKING SYSTEM - PLASTIC

FINS FOR INSERTION

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Winter 2021

ARCH 702 205

PANEL MOUNT SLOTTED JOINT

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1

2

3

4

Circularity via Effective Resource Utilisation

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Isabelle Jackson + Alexander Mayhew BLA BLA BLA

Jellybean Project YOUR NAME OR TITLE Andrew Burnyeat, The

The Jelly Bean Project is an investigation of remote additive manufacturing. The objectives of the project is to revive the abandoned ocean side towns of Newfoundland, by utilizing the benefits of micro factories and additive manufacturing.

This project aims to bring together User Relationships, Local Materials and a Microfactory to reinforce how digital fabrication can be re-distributed to a remote place. The three work together to revitalize the site, using a low environmental impact fabrication technique while still creating opportunities for customization.

Based on location an economy is created surrounding five programs with unique user relationships. We developed several voxels that would house various program sizes.

The materials and their fabrication in the micro facility develops our geometry which is constrained to the voxels to fit within the larger system. The Aggregation of the forms, with the customized geometry will piece together a building.

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3d Printing. MicroFactory. NewFoundLand

tom tio iza n

Re vit ali za

s Cu

tio n

User Relationships

Evironmental Impact

Micro Factory

Site Materials + Location

User Relationships

Economy Site

Building

Form

Site Materials + Location Geometry

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Winter 2021

Micro Factory

ARCH 702 209

Mud Frontiers Rael San Fratello

Digital Construction Platform Steven Keatin, Neri Oxman - MIT

Kit of Parts Branch Technology

Robotics R-IGLO Royal 3D

Branch Technology

The Why Robotic fabrication, and additive manufacturing using local materials is the basis of the project. Specifically, methods of clay extrusion, multi robot micro factories, and state of the art digital construction platforms that can handle unique topography.

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Ornamentation

Wormhole Library MAD

Triple S SRI

3d Printing. MicroFactory. NewFoundLand

Ceramic Tiles Studio Rap

Customization

Zero Waste Lab

Re-Fabrication

• • • •

Kit-of-parts aggregations using vault logics and shell logics Customization of 3d printed components Ornamentation that could result from 3d printing How the components could potentially be broken down and re-fabricated into new parts

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Clay / Silt / Loam

most littered locations

ocean plastic research

ghost towns

Material Selection Clay was the chosen additive manufacturing material of choice, which indicated that Newfoundland could be a possible site for a remote digital fabrication architectural project. Through initial site research Newfoundland indicated there was a plastic crisis going on with a lot of polluted coastlines along the island scattered with ocean plastic and ghost gear washing up on along the shores.

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3d Printing. MicroFactory. NewFoundLand

British Harbour

Site Selection Through the triangulation of geotechnical soil reports, coastline pollution studies, ocean plastic collection points and abandoned communities “ghost towns”, the British Harbour site was selected.

Located within Newfoundland’s Trinity Bay, the harbour is fairly secluded from the bay while still being close to the Atlantic Ocean.

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The Atlantic Ocean Newfoundland Coastline

Fishing + Cleanup

Fishing Tourism

Ocean Plastic Research Institute

British Harbour Workers Housing

Newfoundland Tourism Ocean Plastic Processing Centre Artist Residency

Job Experience Income Investment Ocean Plastic Research Outgoing Payment Experience + Memories

The British Harbour Site Economy Five unique programs work together to build a circular economy centred around ocean plastics. As plastic becomes an increasingly important ocean issue this new community would provide income to fisherman to go out and fish for plastics. They would bring them back to a recycling processing centre, where filament would be created for artists to develop new products and fashion local workers and residents can purchase. This system would draw in tourism for people to come join the clean-up, learn how to work with recycled plastics and learn about the research going into locating, capturing and reusing ocean plastic at the research institute.

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Fishing

Fishing Tourism

Cleanup

Ocean Plastic Research Institute British Harbour Workers Housing

3d Printing. MicroFactory. NewFoundLand

The Atlantic Ocean Newfoundland Coastline

Newfoundland Tourism Ocean Plastic Processing Centre Artist Residency

The Jelly Bean Program Adjacencies The five programs are fishing tourism, ocean plastic research institute, ocean plastic processing centre, artist residency and workers housing. While each of the programs have their own roles and functions, their relationships to each other are critical to see this area become revitalized and activated.

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Localization Plan Welcome to British Harbour, the new revitalized coastal community working on turning ocean plastic into a commodity and building material. The localization plan highlights where the Ocean Plastic Research Institute, Workers Housing, Ocean Plastic Processing Facility, Fishing Accommodation, Fishing Lodge and Artist Residencies are situated on the landscape. The piers and board walks create spaces for all types of vessels to inhabit the bay 216 RE : DISTRIBUTED MACHINES

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WASP

TerraPerforma - OTF 2016/2017 IAAC

Clay The site is home to an abundance of clay, silt and loam. Clay is material that can be used as a load bearing structure that is highly customizable and can be 3D printed with a lower environmental impact than conventional methods such as concrete.

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3d Printing. MicroFactory. NewFoundLand

Mesh Mold Gramazio Kohler Research

Design Miami Pavilions SHoP Architects + Branch Technology

Plastic The coast of Newfoundland harbours a large amount of plastic waste. Ocean plastic presents the opportunity to create building components from a recycled material. Plastic can be 3D printed in free form allowing for design flexibility, and its material properties means it can be used for a wide variety of applications

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Gothic

Rib

Karamba Study

Earthen

Nubian Masgum Dwelling Cameroon

Form The optimal structure shape when building with clay is the vault.

A Gothic style vault with a rib system maximizes the flexibility of interior spaces while allowing for aggregation and future expansion. Conducting a structural study in Karamba refined the from for optimal structural performance.

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54 + dgree shift Add 5% Sand, 5% Fibers, 5% Proteins

Stage 2

12-54 degree shift Add 3% Sand, 4% Fibers, 3$ Proteins

3d Printing. MicroFactory. NewFoundLand

Stage 3

Stage 1

0-12 degree shift No additives required

Clay Printing Material Research - OFT 2016-2017 - IAAC

Sand

Saw Dust

Collagen

Granularity Decreases Brittleness

Fibers Increases Tensile Strength

Protein Increases Elasticity

Material Additives To maximize the structural performance of the clay, it is important to introduce additives to the clay mixture throughout the clay printing process.

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ABB 4600

1.5mm Plastic pellet fed, heated end effector

ABB 4600

Plastic Gripper + Heat gun / Plastic welding pen

Plastic Printing Research has shown that a lattice or mesh structure reduces the overall amount of material, decreases print time by up to 30% and increases overall production by 20% compared to a standard gantry style additive manufacturing process. Free form printing allows the mesh to be made in any direction and then easily pieced together and welded to sculpt various spatial forms. Here is a printing path / process for the robotic fabrication to follow.

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3d Printing. MicroFactory. NewFoundLand ABB 4600

20 - 50mm Clay Extruder

20mm Print Layer x 20mm Print Thickness

20mm Layer x 40mm Thickness

20mm Layer x 50mm Thickness

Clay Printing The clay is printed in a 20mm thickness layer through additive manufacturing and printing as wide as 50mm. First the clay is printed on it’s own without any plastic because it is self supporting.

At the two meter mark plastic is inserted into the print in smaller chunks and the clay continues to be printed around, securing it in place. Plastic components are welded in place as clay continues to print. The clay eventually prints on top as an exterior protection.

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1.

2.

3.

4.

5.

6.

Site Sequencing 1. Required Site Equipment 2. Equipment Deployment and Clay Extraction 3. Collection of Plastic and Processing 4. Site Excavation 5. Plastic Eggshell Placement 6. Clay Printing within the Eggshell

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8.

9.

10.

11.

12.

3d Printing. MicroFactory. NewFoundLand

7.

7. Piloti Tops Printed in Micro Facility and Placed on Site 8. Piloti Tops Welded Together 9. First Floor is Printed 10. Vault Leg and Wall Components Start Printing 11. First Plastic Vault Component Locked into Opening 12. Additional Plastic Conduit and HVAC Components Placed

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13.

14.

15.

16.

17.

18.

13. Windows Printed in Micro Facility and Place in Wall 14. Remaining Vault Leg and Wall Component Printed 15. Plastic Vaults are Placed 16. Plastic Vaults are Welded 17. Vault Top is Printed 18. Aggregation of Vaults

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3d Printing. MicroFactory. NewFoundLand

Fabrication Facility The fabrication facility, or microfactory, creates the plastic components supplied to all of the other programs on the British Harbour revitalization site.

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Deployment

Clay on Site

Stage 1

Plastic from Ocean

Workers Housing

Stage 2

Ocean Plastic Processing Centre

Artist Residencies

Fishing Tourism

Stage 3

Ocean Plastic Research Institute

Processing Centre and Fab Lab

Fabrication Facility Logistics The first step is the plastic collection and preparation and extraction of clay from the site. These are used to create the first stage of the fabrication facility. When this phase is complete, the facility can begin producing the plastic for the housing programming, the fishing lodges, and more components for its own expansion.

Stage two sees a larger fabrication facility capable of producing the parts for the artist residences and the plastic research institute. Finally, stage three removes some of the robots and converts the space into a maker space fab lab for the residents of the site.

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Foundation | Piloti Rounded Single Storey

Flat Topped

Soft Single Storey

Flat Connectors

Short

P1.1

Wide

P1.5

Wide

L1.a

Wide

L2.a

Wide

L3.a

Narrow

L6.a

Common

P1.2

Flare

P1.6

Flare

L1.b

Flare

L2.b

Flare

L3.b

Short

L6.b

Edge

P1.7

Vault

L1.c

Vault

L3.c

Long

L6.c

Column

L3.c

Walls

Door

Garage Door

Opening

Furniture

Containers

Shelves

Shelves

Windows A

Windows B

3d Printing. MicroFactory. NewFoundLand

Piloti Hight

Windows C

Fabrication Facility Menu The overall menu shows the various parts the team is using to create the geometry- starting at a base level and modifying and customizing where needed. The components highlighted in red are specific to the fabrication facility.

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Incoming Plastic

Preparation

Feeding

Shredding and Hopper

Hoses to Robots

Storage and deployment

Plastic Processing The flow of the plastic through the facility is the driver for the geometry of the overall building. First, the incoming PET and HDPE is kept in storage embedded wall units until ready for use. Then, the plastic is prepared through and a washing and drying process, and caps or other plastics are removed.

The plastic is then gravity fed down a conveyor belt with the help of the site grade, and into a large customized shredder and attached pellet hopper. The hopper feeds the pellets into a hose that is attached to the underside of the vaults and can move easily with the robot arm. Finally, components are storage on embedded wall shelves or in the larger storage floor until ready to be picked up and deployed to the individual sites.

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3d Printing. MicroFactory. NewFoundLand

Stage 1 Stage 1 is the half size of the overall fabrication facility. The full vaults geometry on grade as well as the inside with how the production of the first plastic components happen.

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Stage 2 This is the full size of the fabrication facility, with the manufacturing capabilities essentially doubled. At this stage the manufacturing would be high paced, with pieces exiting the facility and going to site quickly.

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3d Printing. MicroFactory. NewFoundLand

Stage 3 Finally, once the vast majority of the plastic components are made, half of the facility converts to fab lab and maker classroom for the artists and anyone else on site who wish to use it. Smaller 3d printers would be added to the facility, with a few larger robots staying for individual use, larger fabrication, and testing capacity for the research facility.

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Fishing Tourism

Andrew Burnyeat

Accommodation Units + Main Lodge Facility These accommodations are for the tourists who have come to British Harbour to participate in Newfoundland’s amazing ocean fishing to take account the hard work that goes into sustainable fishing methods. These units will also host environmentalist who wish to participate in clean up our oceans and shorelines. This program is to attract people looking for meaningful vacation that contributes to a global issue and offer funding to the on going research into the plastic crisis. The Main lodge would host a communal settings for residents to spend time with each other getting to one another.

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Clean Up

Funding

Economy

Fabrication Facility

Research Center

Artist/Workers Residence

Why Tourism Fishing is an important part of maritime identity, creating a unique opportunity to introduce fishing tourism to help reinvigorate the ghost towns of Newfoundland.

Tourism can provide the funding needed to continue plastic recycling research, and ultimately the plastic clean up along Newfoundland’s shores.

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Privacy

3d Printing. MicroFactory. NewFoundLand

Views

Proximity

Tourism Precedents Examining Newfoundland’s coastal buildings, remote tourist lodges and accommodation or ‘glamping’ cabins, specific characteristics stood out; Views of the Landscape, Privacy or Seclusion and Proximity to the Ocean.

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Spatial Rational

Shape Grammers

1

2

3

4

5

6

7

8

1

2

3

5

6

7

Accommodation Unit

4

Main Lodge

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Common Space

Large W/C

Dining Room

Kitchennette

Living Room

Bed Room

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Small Deck

Kitchen

Small W/C

Storage Room

Large Deck

Views

Privacy

Views

Privacy

Winter 2021

3d Printing. MicroFactory. NewFoundLand

Programs Elements

ARCH 702 239

Accommodation Units

Level 1

Piloti

Level 2

Accommodation Unit Vaults To define the Program Diagrams, the vaults are placed within the voxels. 3D printing allows for a variety of custom vault legs.

The first floor utilizes thicker vault legs around the perimeter with the thinnest vault legs near center and top floor.

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Least Glazing Privacy

Views

Privacy

3d Printing. MicroFactory. NewFoundLand

Most Glazing - Views - Social Areas

Other

Accommodation Unit Walls With the vaults creating the spaces, a variety of customizable walls were created to define the programs of each interior space.

Walls customized for views were are placed around public spaces such as living rooms, kitchens, and dining rooms, while walls customized for private spaces are placed around the wash room.

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Views - Kitchenette

Views - Living Room

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3d Printing. MicroFactory. NewFoundLand

Privacy - Bathroom

Privacy - Bedroom

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Accomodation Unit These accomodation units are design for one to two people, featuring basic amenities including a kitchenette, living room, master bedroom and full sized washroom. the building is oriented to maximize views of the bay while maximizing privacy.

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Main Lodge

Piloti

Level 1

Level 2

Main Lodge Vaults The first floor utilizes thicker vault legs around the perimeter with thinner vaults in the center to maximize social space.

The thinnest vault legs are located on the second floor to create larger openings for the living room.

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Least Glazing Privacy

Views

Privacy

3d Printing. MicroFactory. NewFoundLand

Most Glazing - Views - Social Areas

Other

Main Lodge Walls Similar to the accommodation units, the walls customized for views were are placed around public spaces such as the common areas, kitchen, and second floor living rooms.

Walls customized for privacy or seclusion were placed around the washrooms and storage room.

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Views - Dining Room

Views - Living Room

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3d Printing. MicroFactory. NewFoundLand

Privacy - Storage Room

Privacy - Washroom

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Main Fishing Lodge A community hub for the tourism sector, including the fisherman and artist residents. It serves as a gathering place with quality amenities including a dinning area, fishing storage populated with the best bay side views out of British Harbour.

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Ocean Plastic Research Institute

Alexander Mayhew

Research Station + Exhibition Hall Located on the Northwest Side of British Harbour, the Ocean Plastic Research Institute is a four level structure that acts as a research station and think tank to discover where ocean plastic is being accumulated along the Newfoundland Coast and Atlantic Ocean. Then the team is tasked with figuring out methods to best collect the floating waste and then how to recycle it into a usable and safe commodity. The top floors of the building are semi public spaces for the community to use as work stations and to gather to learn about the on going efforts to track down the pollution issue and exhibit their latest findings.

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3M tone Plastic waste is trashed

every year by Canadians

(Environment and Climate Change Canada, November 2020)

(Environment and Climate Change Canada, April 2021)

(Fisheries and Oceans Canada, January 2021)

Plastics Crisis As Canada strives to achieve Zero Plastic Waste by 2030 it highlights the need for a Plastic Research Centre that would be exploring our plastic crisis. While today we see Canadians creating 3 million tones of waste every year only 9% of that plastic is recycled. More and more we hear about plastic ending up in our oceans but here in Newfoundland we see a huge issue of ghost gear impacting our environment.

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Increasing Knowledge on Plastic Pollution (IKPP) Initiative (Environment and Climate Change Canada, November 2020)

Ghost Gear Fund

Eliminate certain sources of plastic pollution Create recycled plastic markets Improve value recovery of plastic products + packaging Support innovation of new technology Support innovation in clean up operations

3d Printing. MicroFactory. NewFoundLand

$2.2M $8.3M

(Ocean Plastic Charter (2018)

Plastic Charter This has led the government to investing in the clean up of our coast lines and investing in plastic research and pollution education. Canada has signed the Ocean Plastics Charter created in 2018 and this facility would be part of this initiative by following these five objectives.

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Knowledge Centre for Plastic + Marine Littering (Expected 2022) Snohetta has begun designing a new institutional building in Osls, Norway focused on educating the public about the impacts of plastic. Showcasing how it’s our responsibility and accountability to take control of our plastic usage.

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Labs

Expo

B.C. Marina Sciences Centre

Workstations

Operations

Expo

3d Printing. MicroFactory. NewFoundLand

Admin

Admin Coastal Marine Research Station

Expo Labs

Memorial University - Ocean Sciences Centre

Research Precedents Looking at three coastal research projects, highlighted are a few similarities between the various projects.

• • • •

Separated programming between admin, labs and exhibitions Views of the ocean, drawing in lots of natural light Facilities are located on the top of the terrain away from the Ocean The facilities have access to the water for their research methods

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COLLECT UNDERSTAND

EDUCATE

INNOVATE

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Presentation Lounge

A2.

Presentation Lounge

A3.

Presentation Lounge

A4. Lounge

A5. Lounge

A6. Exhibition

A7. Mudroom

A8.

B1. Reception

B2.

C1. Library

C2. Library

C3. Library

C4. Library

C5.

D1. Kitchen

D2. Dinning

D3. Dinning

D4. Dinning

D5. Dinning

E1.

E2.

F1. Workstation

F2. Workstation

H1.

H2. Assembly

Research Lab

Office

Research Lab

F3. Boardroom

G1. Washroom

H3.

H4.

Creation Lab

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Computer Lab

Fabrication Robotic

Locker Room

3d Printing. MicroFactory. NewFoundLand

A1.

Material Library

Winter 2021

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Dock Shipping + Receiving

Storage Creation Lab

Research Lab Assembly + Fabrication Computer Lab

Admin Management

Material Library

Public Entrance Exhibition Gallery

Social Interaction

Lockers + Restroom

Kitchen

Dinning

Co - Working Space

Presentation Lounge

Program Adjacencies

Volumetric Conversion 260 RE : DISTRIBUTED MACHINES

Circularity via Effective Resource Utilisation

2

3

4

5

6

7

8

3d Printing. MicroFactory. NewFoundLand

1

9

a

b

c

d

e

Shape Grammar

Level 1

Level 2

Fabrication Level

Research Level

Reference Level

Exhibition Level

- Creation Lab - Fabrication - Shipping + Receiving - Assembly - Storage

- Labs - Work Stations - Meeting Room - Supervisor Office

- Material Library - Cartography - Literature - Computer Lab - Work Stations - Meeting Rooms - Lockers + WC

- Reception - Mud Room - Exhibition - Kitchen - Dinning - Social Interaction - Presentation Lounge

Level 3

Level 4

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Program Isometric Winter 2021

ARCH 702 261

Rounded

Narrow

L1.c

Single Storey

Second Storey

Narrow

Narrow

L3.c

L5.a

Barrel Vault

Narrow

L6.a

Column

L1.c

Column

L3.c

Column

L5.a

Short

L6.a

Vault

L1.c

Vault

L3.c

Vault

L5.a

Long

L6.a

L1. Arch

L3. Arch

L5. Arch

L6. Arch

L1. Arch Split

L3. Arch Split

L5. Arch Split

L6. Arch Split

L1. Connectors

L3. Connectors

L5. Connectors

L6. Connectors

Hight Supports

Flat Connectors

Narrow

Quarter

L6.a

Plank

L6.b

L4. Connectors

Square

L6.c

Narrow

Flat Connector

Edge

Vault

L4.c

L4.c

L2.c

L2.c

Corner Connector

L2. Connectors

Vault Typologies Vault legs are designed for its each own unique condition, foundation, single storey or second storey placement. Depending on the location of the vault a different leg could be used for a more customized exterior and interior look and feel. These pieces would then come together to build up a vaulted space.

Barrel vaults and flat connectors allow create opportunities for expanding changing the interior spaces.

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Walls

Glazing

Furniture

Doors

Double Height

Short

P1.1

0% openings

80% Openings

Light Shelves

Doors

Straight Stair

Common

P1.2

10% openings

80% Center

Shelvings

Doors

U - Shaped Stair

Long

P1.3

20% openings

85% openings

Bar Tops

Half Open

Vaults Stacked

XLong

P1.4

20% Center

95% openings

Lockers

Open

Edge

P1.7

5% openings

95% Center

Cubicals

Closed

Column

P1.7

Flat Walls

100% openings

Balcony A

Balcony B

3d Printing. MicroFactory. NewFoundLand

Foundation

Components With a variety of different leg types, connectors were developed so the walls could be shaped commonly while focusing on creating unique conditions. Each wall is customized to reflect the experiential aspects of the user relationships happening within.

Some vaults are designed to be able to stack and two different stair types allow the vaults to be fully integrated.

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Vault 50.1

Vault 100.1

Vault 100.7

Vault 150.1

Vault 200.1

Vault 50.2

Vault 100.2

Vault 100.8

Vault 150.2

Vault 200.2

Vault 50.3

Vault 100.3

Vault 100.9

Vault 150.3

Vault 200.3

Vault 50.4

Vault 100.4

Vault 100.10

Vault 150.4

Vault 200.4

Vault 100.5

Vault 100.11

Vault 150.5

Vault 200.5

Vault 100.6

Vault 100.12

Vault 150.6

Vault 200.6

Variations The flexibility in the modularity of the various components leads us to where we can begin to see different combinations and opportunities the vault legs provide. Different vault conditions allow for different programs to occur beneath them.

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Walls

First Storey Vaults

Connectors

Fenestration

Foundation Vault

Furnishing

3d Printing. MicroFactory. NewFoundLand

Second Storey Vaults

Extensions

Piloti

System Assembly Due to the large building size, the system had to be robust enough that everything was modular but created an opportunity for customization that allows pieces to be added or removed based on the needs of the researchers. In the simplest terms the system breaks down into a foundation, single storey and second storey vaults with various extensions, walls, connectors, fenestrations to match the vault leg used.

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Views from the Research Vessel The Ocean Plastic Research Institute sits on the hill side, with the board walk leading to two research vessels waiting for the researchers and sailors to climb aboard.

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Presentation Lounge

Co-Lab Space

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3d Printing. MicroFactory. NewFoundLand

Material Library

Cartography Space

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Ocean Plastic Research Institute The building becomes a landmark on the landscape and a reminder how big of a plastic issue we are dealing with and we need to take immediate action on reducing our footprint. We don’t need a huge facility to tell people to stop producing plastic.

We need a place for big ideas to take shape to tackle our ocean plastic crisis.

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The Jellybean Project: AM Housing

Thomas Acheson

The Jelly-Bean Project: AM Housing This project situates itself as a component of an overall revitilization project in a current ‘Ghost Town’ site along the Newfoundland coastline while leveraging the clay soil and plastic found in and around the site as its primary construction materials.

Thus this project looks to leverage current additive manufacturing methods to not only reconsider architectural fabrication in the digital age, but a new conceptual and environmental framework for it.

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3d Printing. MicroFactory. NewFoundLand Ghost Town

Robotics

Revitalization

User Relationships

Introduction

za ti

n tio

iza

Re vit ali

m sto

Cu

on

Project Aims + Structure

Environmental Impact

Site Materials + Location RE : DISTRIBUTED MACHINES

Micro-Factory Winter 2021

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The Why Opportunities in AM

Herman Hertzbergar, Central Beheer Offices

Buckminster Fuller, Diamaxyion House

LEGO Red and Yellow Car Set 1606 Instructions

Restablishing Norms

Innovating Typical Construction Practice

Embedded Complexity ‘Free’ Detailing

Kit-of-Parts

Leveraged through Digital Fabrication

The New Economy Localization Plan Ocean Plastic Research Institute

Plastic Micro-Factory/Fab-Lab

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Housing

Fishing Residency

Artist Residency

Circularity via Effective Resource Utilisation

Project Siting

British Harbour

Predominantly Clay Based Soil Most littered Beach Fronts Ocean Plastic Research ‘Ghost’ Towns

Eating

Opaque

3d Printing. MicroFactory. NewFoundLand

The New Economy

The ‘How’

Transparent

Eating (Prep.)

Project Aims

Sleeping Congregating Relaxing Hygiene Eating Eating (Prep.)

Sleeping Congregating Relaxing Hygiene

Eating Eating (Prep.)

Sleeping Congregating Relaxing Hygiene Eating Eating (Prep.)

Sleeping Congregating Relaxing Hygiene

Customization As Foundational Process

RE : DISTRIBUTED MACHINES

Reconsidering Housing Models Programming Digital Fabrication

Environmental Impact New Ways to Leverage Resources

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The Materials In-Situ

Clay Based Soil

Plastic

Group Logics General

Catenary Logics

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Vault Based Structures

Earth Based Structures

Circularity via Effective Resource Utilisation

Preliminary Exercise

Generic Housing

Living Room

Dining Room

Kitchen

Prelim. Housing

Vault Primitive

Bedroom

Bathroom

Office/ Storage

3d Printing. MicroFactory. NewFoundLand

Vault/Housing Application

Primitive Development Aggregating Vaults

Vault Primitive

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5-Bed

Prelim. Amalgamation (Selected Primitives) Translating Primitives to Program

Bachelor

1 Typical Program (2-Bed Detached)

2 Program as Volume

3 Divided Volume

Prelim. Amalgamation (Selected Primitive) Translating Primitive to Program

Step A.c

Step 1.1

Step A.b

Step 1

Step A

4 Re-Organization Sequence

Sequence

5 Re-Programmed

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6 Selected Primitive Applied

7 ‘Rough’ Application to Site

Circularity via Effective Resource Utilisation

Fabrication

Armadillo Vault ETH Zurich

AM Along Stress Lines DSpace@MIT

Polybrick 2.0

3d Printing. MicroFactory. NewFoundLand

Precedent

Openings in 3d Printing

JSLab Cornell University

IAAC

Primitive Modification Structural Parameters

Selected Primitive

Catenary Alteration

RE : DISTRIBUTED MACHINES

Utilization

Openings Based on Utilization

Winter 2021

Principle Stress Lines

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Primitive Modification Structural Parameters

Segmentation: Robotic Extents

Segmentation: Staggered Bond + Simplified Stress Lines

Floor/Transitory Components

Segmented Primitive

Primitive Library Clay Segment Re-assembly

Constituant Segements

Non-Orthogonal Connections

Full Vaults

Base Primitive

280 RE : DISTRIBUTED MACHINES

Circularity via Effective Resource Utilisation

Robotic Parameters

Stress Lines to Toolpath

Robotic Extents

3d Printing. MicroFactory. NewFoundLand

Primitive Modification

Stress Lines to Segment

Plastic Printing

Off-Site Fabrication

Robotic Parameters (Off-Site)

Segmentation

Robotic Extents

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Construction Process 1

Deployment

2

Equipment unloaded to site.

8

Assembling printed clay segments via robot mounted to boom-lift w/ ‘gripper’ attachment.

3

Excavating for site-work: utilites, foundation, grading.

7

Assembling Segments

Excavation

Placing Segments

Transporting printed clay segments to installation point via excavator.

Processing

4

Printing Kiln

Process. excavated clay: sieving, add. chemical additives/fibres, water, mixing.

Pumping processed clay to extruder(s) mounted to robot.

6 Firing Segments

Extruding clay to create kiln via robot mounted to boom-lift.

Transporting printed clay segments from printing area to kiln for firing via excavator.

Extruding clay to create clay segments via robot mounted to boom-lift.

5

Sequence

Printing Segments

Construction Process Equipment

Trailer 1

2000kW Site Generator Trailer Clay Additives - (truck)

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Trailer 2

Clay Mixer Clay Pump 2x Robots

Trailer 3

Excavator Misc. Construction Equipment Clay Additives - (truck)

2x High-Float Telescopic Boom Clay Additives - (truck)

Circularity via Effective Resource Utilisation

General Deployment

1. Deployment 2. Excavation 3. Processing 4. Printing Kiln

3d Printing. MicroFactory. NewFoundLand

Construction Process

5. Printing Segments 6. Firing Segments 7. Placing Segments 8. Assembling Segments

Construction Process Excavation

1. Deployment 2. Excavation 3. Processing 4. Printing Kiln 5. Printing Segments 6. Firing Segments 7. Placing Segments 8. Assembling Segments

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Construction Process Printing Segments

1. Deployment 2. Excavation 3. Processing 4. Printing Kiln 5. Printing Segments 6. Firing Segments 7. Placing Segments 8. Assembling Segments

Construction Process Placing Segments

1. Deployment 2. Excavation 3. Processing 4. Printing Kiln 5. Printing Segments 6. Firing Segments 7. Placing Segments 8. Assembling Segments

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Circularity via Effective Resource Utilisation

Placing Segments

1. Deployment 2. Excavation 3. Processing 4. Printing Kiln

3d Printing. MicroFactory. NewFoundLand

Construction Process

5. Printing Segments 6. Firing Segments 7. Placing Segments 8. Assembling Segments

Construction Process Placing Segments

1. Deployment 2. Excavation 3. Processing 4. Printing Kiln 5. Printing Segments 6. Firing Segments 7. Placing Segments 8. Assembling Segments

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Construction Process Placing Segments

1. Deployment 2. Excavation 3. Processing 4. Printing Kiln 5. Printing Segments 6. Firing Segments 7. Placing Segments 8. Assembling Segments

Construction Process Placing Plastic

1. Deployment 2. Excavation 3. Processing 4. Printing Kiln 5. Printing Segments 6. Firing Segments 7. Placing Segments 8. Assembling Segments

286 RE : DISTRIBUTED MACHINES

Circularity via Effective Resource Utilisation

Base Primitive

Typ. Panel Mount

Typ. Slotted Joint

Typ. Ball Joint

3d Printing. MicroFactory. NewFoundLand

General Construction Details

Panel/Wall Junction

General Construction Details Floor Construction Logic

50mm Topping Slab

100mm Plastic Slab 760mm Plastic Framing

305mm (w) Plastic Deflection Joint

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Precedent Housing

Spacing Trading

Narkomfin

AADRL

Moisei Ginzburg

The Trulli of Alberobello

Housing Rules Quantifying Components

8 Wall Panels 8 Upper Panels

288 RE : DISTRIBUTED MACHINES

20 Segments

Circularity via Effective Resource Utilisation

Harvesting Plastic Encourage Harvesting of Ocean Plastic

Processed Plastic

Individual Allotment

+/- 17m3 Total Volume of Processed Plastic Required

Excavation Discourage Further Excavation of Site.

Processed Clay +/- 12m3 Volume of Processsed Clay Required.

8 Wall/Furniture Components 8 Upper Panels

Individual Allotment +/- 20 Clay Segments

Communal Allotment +

+

16 Wall Components

Communal Allotment +/- 40 Clay Segments

3d Printing. MicroFactory. NewFoundLand

Housing Rules Clay + Plastic Consumption

Housing Rules Activity + Separator

RE : DISTRIBUTED MACHINES

Winter 2021

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Interior Render Communal/Transparent

Interior Render Individual/Opaque

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Circularity via Effective Resource Utilisation

Communal Base

Net Clay Component Addition

Communal Allotment

Eating

Opacity

Transparent

Opaque

Eating (Prep.)

3d Printing. MicroFactory. NewFoundLand

Housing Rules Volume of Plastic Addition

Sleeping Congregating Relaxing Hygiene

Housing Rules Volume of Plastic Addition

+ Household (1 person)

Net Clay Component Addition

Communal Allotment + Household (1 person)

Eating

Opacity

Opaque

Transparent

Eating (Prep.)

Sleeping

Bob

Congregating Relaxing Hygiene

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Housing Rules Volume of Plastic Addition Household (+1 person)

Net Clay Component Addition

Communal Allotment + Household (1 +1 person)

Eating

Opacity

Transparent

Opaque

Eating (Prep.)

Sleeping

Linda

Bob

Congregating Relaxing Hygiene

Housing Rules Volume of Plastic Addition + Household (2 person) + Household (3 person) + Communal Adjustment

Net Clay Component Addition

Communal Allotment + Household (2 person) + Household (3 person) Eating

Opacity Opaque

Transparent

Eating (Prep.)

Sleeping

Andy

Jim Jr.

Jimmy

Linda

Bob

Congregating Relaxing Hygiene

292 RE : DISTRIBUTED MACHINES

Circularity via Effective Resource Utilisation

Resultant Form Ex.

RE : DISTRIBUTED MACHINES

Winter 2021

3d Printing. MicroFactory. NewFoundLand

Housing Rules

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Circularity via Effective Resource Utilisation

3d Printing. MicroFactory. NewFoundLand RE : DISTRIBUTED MACHINES

Winter 2021

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Work produced by Senior Architecture Studio Studio 6 ARCH 702 (Re) distributed machines

https://sapl.ucalgary.ca/

Copyright 2021 University of Calgary School of Architecture, Planning & Landscape All rights reserved.

No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage and retrieval system without permission in writing from the publisher.

Instagram: @ucalgarysapl Twitter: @ucalgarysapl

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Circularity via Effective Resource Utilisation

{Re} Distributed Machines

STUDIO RE : DISTRIBUTED MACHINES

6

Winter 2021

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{RE} DISTRIBUTED MACHINES Prefabricates have become the efficient off-site, quantifiable, machinic alternative to traditional construction methods. However, they result in centralized models of architectural production. 87.5% of building sites are not accessible to prefabricates amongst other things due to the non-standard site condition, being on a remote location or in a central place in which machines will be incredibly disruptive. Additionally, costs of transportation and specific design requirements need to be analyzed. The lack of skills increased by a situation like the COVID-19 pandemic invites us to question: how are the spaces created by these ‘construction factories’ better than spaces from previous centuries. Moreover, how can we design for manufacturing optimizing machine and resource utilization to design an architecture in which form follows resource availability.

Robotic fabrication and industrialized construction for resource-effective physical realization of the built environment is the best solution for a construction industry, one of the least productive, more polluting industries.

COVID has changed the meaning and use of spaces, houses that were mainly used as sleeping quarters are now offices, party places and social spaces that host all our professional and social activities.

The studio foresees architectural solutions that REdistribute and democratize digital design and digital fabrication. It proposes to investigating how the added degrees of freedom enabled by digital fabrication can result in more fluid creations that blend modes of use and user experiences for the same space. Through the use of architectural geometry, shape design and emerging fabrication technologies, the studio expects the creation of physically realizable, ecologically sound, structurally effective assets that shape the built environment.

YOU CAN ONLY BRING THE MACHINES. USE THE LOCAL RESOURCES, CREATE THE RULES. DESIGN THE SYSTEM CIRCULARITY VIA EFFECTIVE RESOURCE UTILISATION