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FOAM FOR FORM UNIVERCITY COLLEGE LONDON, BARTLETT SCHOOL OF ARCHITECTURE, LONDON 2017-2018 Tutors: Daniel Widrig, Guan Lee, Stefan Bassing, Adam Holloway Group Members: Charbel Chagoury, Chrysoula Katsampe, Wenqian Yang Junzhuo Zhang


AGENDA The agenda of this project is to study material behavior and develop form finding method based on material properties and external constraints. The workflows between digital generation and fabrication processes across scales are explored, with the aim to innovate upon the interactions of the digital and material realms. In this project, multiple methods have been tested to manipulate the deformation of polyurethane. Precise overall control, clear expression of input information and unprecedented aesthetic details composed from multiple layers are the main issues to address during the progress.

-Experiments of foam properties of different types Extruded Polystyrene

Expanded Polystyrene

Liquid Polyurethane

Feature

Flexibility Density

-The most flexible foam: Polyurethane -Polyurethane in different forms and dimentions Thin Sheet

Pipe

Block

Polyurethane


STITCHING EXPERIMENTS ON POLYURETHANE SHEET

Stitching Pattern

Physical Deformation

Digial Simulation


STITCHING EXPERIMENTS ON POLYURETHANE TUBE

STITCHING EXPERIMENTS ON POLYURETHANE BLOCK

Stitching Pattern

Stitching Pattern

Physical Deformation

Physical Deformation

Digial Simulation

Digial Simulation


COATING STRATEGY Coating Method Comparison

Feature

Application

Polyurethane Coating Process

Different Spraying Results

Flexibility

Gloss Epoxy

Impact Resistance water proofing

Initial Product

1 Layer

Rubber Coating

Water Resistance UV Resistance Strength water proofing

Spray Coating

2 Layers

Polyurethane Coating

Impact Resistance Abrasion Resistance Fire Retardancy water proofing

Strengthened

4 Layers


COMBINATION OF WORKFLOWS Deformation Pattern

Digital Simulation

Fabrication

Refining Surface


SHELL SPACE UNIT DESIGN - DIGITAL APPROACH Prototype and Pattern Generation

Initial Geometry

Generating Process Simulation

Load and Support

Stitching Simulation

Optimization on the Unit

Stitching Pattern Generation

Sewing Simulation

Coating Simulation


DIGITAL DESIGN RESULT Variations

Folding the panel to form the shell space

Panel A

Panel B

Panel C


SHELL SPACE UNIT DESIGN - FABRICATION APPROACH Compressing - Increase Stiffness

Stitching - Form Influence

Coating - Strengthening & Refining

Scaffold - Installing


FABRICATION RESULT Folding the panel to form the shell space

Variations

Panel A

Panel B

Panel C

Foam for form_bartlett rc5&6 2018s  
Foam for form_bartlett rc5&6 2018s  
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