Portfolio Year 3 - Semester 1

LEUNG POK YIN, VICTOR2008094825

THE UNIVERSITY OF HONG KONGDEPARTMENT OF ARCHITECTURE

ARCH3013YAN GAO

FIRST SEMESTER, 2010

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Table of Contents

Project 2 : Components and SystemsZip Bending Research

Project 2a : 17th September - 30th September

Lattice Fabrication - Y system Project 2b : 1st October - 14th October

1 Degree Bending - Spring system Project 2c : 24th October - 30th October

Project 1 : Case StudyLookout Tower by Villa Hara

Project 1 : 1st September - 16th September

Project 3 : Pavilion Prototype2 Degree Bending - 3D Bending Pavilion

Project 3 : 2nd November - 30th November

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Korkeasaari Lookout Tower by Ville HaraA structural analysis of the pavilion done in Finland by students from Helsinki University of technology.

The diagrid structure allows the surface to be structural while transparent.Image courtesy: Avanto Architects

Analysis

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penkki

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6016

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SectionsThe structure transfers all loads by the diagrid to the ground which rests on shallow inserted foundation. The structure is ideal for its porosity and rigidity.Image courtesy: Avanto Architects

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Ring Beam of the Floor SlabsThe slab is supported by two wooden rings in the periphery, in order to produce the precise curvature, 8 layers of wood are laminated and moulded with a curved formwork. These drawings show the precise measurements used for building the formwork. Sectional dimension of beam 100X250mm. Image courtesy: Avanto Architects

Analysis

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11111 1 1 1111 222221 3 3 3 32 4 4444 42 555555 5 5 5 55 5666666 6 6 66 655 6 76

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Bending the DiagridEach wooden member of the diagrid is unique, however, to standardize fabrication, they are unfolded (with curvature distor-tion) from 3D to 2D, sorted into seven moulds that is used to make the glue lamination (4 layers). The 2D curved timbers are then forced into a 3D curve during the assembly process. Sectional dimension: 60X50mm

These members became rigid only after assembled to a diagrid lattice; they each have a flattening force that counterbalances the opposite direction members in the diagrid.Image courtesy: Avanto Architects

Analysis

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Parametric Modelling

Based on the drawings from the architect Ville Hara, a Grasshopper script is developed to receive a NURBs surface and build a 3D diagrid structure model based on parameters such as density and thickness.

Scripting

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Zip Bending ResearchA parametric way of controlling wood bending

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Inspiration from ZipshapeThe technique of bending wood sheets developed by Christoph Schindler allows the creation of bent timber forms without the use of moulds. Dealing with the problem of numerous formworks that is required to produce the bent timber in the Lookout Tower, this research focus on the fabrication of curved timber piece, that utilize and extends the idea by C. Schindler, by looking into the possibility of bending a straight timber in two degrees. Image courtesy: schindlersalmerón schindlersalmeron.com

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CNC FabricationC. Schindler designed the whole process of digital calculation, cutting machineries and assembly procedures for bending a timber sheet.Image courtesy: schindlersalmerón schindlersalmeron.com

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Conceptual Research - 2D CurveThe logic of bending with teeth is to force one teeth into a slot of the opposite component, the tab and the slot have sightly difference in geometry which forces the thin linkage connecting the teeth to be bent. The outcome is a curved that is fabricated directly from a digital curve input.

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Apple Chan . Victor Leung . Huang Zhiyun Wendy

Testing Model of di�erent connection for modules growing in 3D continuously

Project 2A: Components and Systems - Modular & Variable Assembly Systems.

2D Line connection

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Conceptual Research - BranchingWe want to explore the potential of the teeth joinery to see if jointing can be done with slight modification of the system. By introducing an additional piece, the linear element could split into two branch.Concept initiated by Wendy Huang




Y connectionResearch

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Fabrication test - RingTo produce a complete ring is a difficult test for the bending system. Slight curvature difference between the digital model and the phys-ical model will make the ring incomplete or overshoot. To tackle the problem, the material behavior is modelled into the fabrication script, taking into account the expansion of the material (here: MDF in our school) during bending.




Looping connection

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SurfaceFurther test on creating a surface with teeth are interesting but proved to be very difficult. Frictional joints employed by Axel Kilian mentioned in his paper “Fabrication of partially double-curved surfaces out of flat sheet material through a 3d puzzle approach” explored similar methodology. This project will therefore not attempt to replicate the effort.




Surface connectionResearch

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Grasshopper ScriptA grasshopper script is written to perform geometric calculation for the bending. Geometric input take a spline curve, numeric parameters include teeth density, joinery angle, material thickness and material response.

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Material ResponseNumerous test piece are produced to verify the script’s ability to calculate the geometry correctly. Which is important to ensure that the script will produce a curve that is similar to the spline input.

Scripting

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Prototyping

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Y-joint test

incomplete ring - discrepancy between digital calculation and fabrication

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Prototyping

testing with walnut wood with 3-axis CNC router experiment with another script that produce a curved surface

double curve surface conceptual model.

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Lattice Fabrication - ‘Y’ System Components and Connections

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Branching without additional pieceTo propose this hypothetical joint which relies on thicker geometry to expand the joint, tries to eliminate the need for an external piece.

However with larger timber diameter, the thickening is not possible without joining together multiple blocks of wood.Concept initiated by Wendy Huang


Parameters to be changed in the system


Variation of angle and length

Angle: 40 Angle: 35 Angle: 25 Angle: 20Length of longest teeth: 12mmLength of longest teeth: 18mmLength of longest teeth: 24mmLength of longest teeth: 27mm

scheme 2

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Additional bending pieceThe additional bending piece allows the timber to be uniform in thickness and cut into teeth. This method reduces the waste material down to minimal. Similar splitting joints with different angles can control the bending amount.


scheme1


Basic Lattice System

Angle: 60 Angle: 45 Angle: 30 Angle: 20

Parameters to be changed in the system Research

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Repeating unit from the branchOne aim of this research is to construct a surface from the proposed system. However, the elements we have studied are all linear elements without a definition of surface or volume. Thus we combined these elements in a much smaller scale to producing a repeating unit that could propagate on a given surface.


Joining of Y shape components perpendicularly by their teeth


Modules Connection

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Jointing MechanismFour branching components adds together to become a repeating unit. The repeating unit is than repeatable in 3 directions.


which will grow continously into a lattice system


Basic Unit

Front view Top view

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Y SystemEach repeating unit can grow in x, y, z directions, a lattice with considerable volume (hence stability) could be formed.


Di�erent view of the system



Side view

Top view

Front view

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Hypothetical LatticeThe wall system started with building a hypothetical lattice that could be deformed by parametric calculation.


Continuous repetitation of the basic unit



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Modelling with paperTo simplify fabrication for testing the system, the wooden piece are represented by cardboard that could be easily laser cut and assem-bled. This photo shows a hypothetical lattice that is assembled with all equal piece.

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Scripting LogicThe relationship between linear elements defines the calculation logic for lengths and angles. Each of the paper components that repre-sent the Y branch system are drawn with the calculation result.

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Scripting

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points are generated from a surface input

connections between points signifies the relationship in between

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lengths and angles are calculated from the points cut files are generated from the numerical results

Scripting

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Controlled lattice with paperThis test piece used 306 unique pieces in assembly, archiving a controlled geometry that resembles the surface modelled in computer.

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Prototyping

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1 Degree Bending

Spring System Spatial system with 1 degree bent timber

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logic of one degree bending - two strands of teeth

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logic of two degree bending - four strands of teeth

Scripting

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Jointing between members It is important for linear members to be able to join, in order to form a more complex structure, we investigated the possibility to slot the linear member into each other with slight modification on the teeth.

90Deg Joint Project 2B: Components and Systems - Modular & Variable Assembly SystemsApple Chan . Victor Leung . Huang Zhiyun Wendy

Achieving 3rd Dimension

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Angled joint with additional pieceTo work around with the limitation that the timber is to be cut with planar cutting tool (e.g. 2 axis water jet cutter). An extra wedge piece is introduced to fill the gap between the slots. This allows two linear members to join with an specific angle.

30 Deg Joint by Triangular Pieces Project 2B: Components and Systems - Modular & Variable Assembly SystemsApple Chan . Victor Leung . Huang Zhiyun Wendy


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Shifting Lamination Technique If the timber is produced by lamination, the angled slot could be incorporated into the laminates, this is a variation of the halved slot joinery without the need to use a gap wedge.

30 Deg Joint by Layers of Lamination Project 2B: Components and Systems - Modular & Variable Assembly SystemsApple Chan . Victor Leung . Huang Zhiyun Wendy


30 deg Joint Gap o�set in di�erent layers of lamination

Five Layer Lamination ExampleTeeth may interlock between Layers

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Spring - Creating space with a one degree bent curve

To explore the potential of the one degree bending, a form that utilize a flat curve is desired in creating an expression of space. We took inspiration from a spring, which has a geometry that is almost flat before stretching, and became three dimensional after. To counteract the compression force, an intermediate structure is placed between the ribs to keep the spring stretched, thereby allowing the space to be occu-piable.The system is very stable due to the counteracting forces, all one degree bent curves found their forms during the assembly process and are kept stable by the connections. (Similar to the outer structure of the Lookout Tower)

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variations of the spring with different profiles

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the sections can be transformed along the spring

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studying a cladding option with teethed edge

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various sectional profiles - potential branching of the structure to from spatial divider

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furniture from the branch

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stick variation - interweaved rods pass through a drilled hole on the rib

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perpendicular fins variation - solar control while encouraging ventilation

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surface clad - stiff boards slotted into the teethes

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surface clad double sided

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linear stick - linear compression sticks allows maximum visual penetration

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Occupying the springThe stretched spring system allows flexibility on designing a linear space that is adaptable to various use. The continuity of the spiral is experienced by the transformation of the profile. Various entrance, glazing, and cladding strategy are able to customize the system.

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Transforming profile test 1The spring is smoothly transforming from a larger triangle profile into a smaller one. The model is cut from planar MDF with slots that receive a paper fin. The paper fins proof the rigidity of the system where the compressive force are regularly distributed.

Prototyping

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Transforming profile test 2This test used a profile that is concave on one side, also transforming from big to small. Density of fins also reduced as proofed sufficient.

Prototyping

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Combined Tube

The limitation of this system is that it can only produce linear space that is defined by the spring. The design can however, combine multiple tubes to create a more complex experience, even breaking the boundary between the definition of inside and outside.

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2 Degree Bending

3D Bending Paviliontimber bending research manifestation

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32 Degree bending - teeth calculationA grasshopper script takes a 3D Spline-curve and divide frames along the curve, the frames are aligned along the tangent of the curve and points are generated from the resulting planes.- The points are relocated, to optimise the limitation from a 2-axes laser cut machine. - Cut files are generated from the distances and angles calculated from those points.

divide curve and generate planes (frames)

distances and angles between points

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fabrication process involves assembling the four strands and gluing them together

Prototyping

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Design Statement

Form FindingThe pavilion exhibits itself as an manifestation of the timber technology de-

veloped earlier. Resulting from the analysis of the system, limitations drive the design of the form.

• The pavilion should make use of the ability of the structure to be very long• The pavilion should rest on the ground without post and beam

• The structure should enclose a large space

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One Loop

The ideal of a loop is a ultimate reduction of components into a unity whole. This variation is an attempt to find am undulating form that defines a space.

space enclosure

access

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Interlocking

The rib can form into a loop that interlocks itself at the top-most point to enhance stability, the arch rest on one another to form a ring. It still maintains its elegance of being one member.

resting on each other

force to the ground

lower part buried below grade

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Additional JointingMore overlapping of the rib with itself can generate more joints between the member, thereby stiffening the structure like a mesh.

resting on each other

additional overlapping / joint

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More members?More members could potentially increase the overlapping chance of the structure, gener-ating a lattice which is complex and strong. This image adds up multiple variations during the form finding sketches.

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Two ribs are enoughCombining previous concepts, two ribs are considered the best compromise. The two ribs wraps in opposite directions, buttressing each other and overlapping in various locations.

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tested forms in the form finding process

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Curve Generation

This is the script that allows the form testing process to happen digitally but as malleable as a paper strip with flexible control. The definition is based on a circle divided with points which is than transformed with different parameters.The points generated an interpolating curve which forms one loop

Optimization

The curve is analyzed with tailored algorithm to find the curvature at various points. An optimization process rebuilds the curves to a smaller and smoother curvature. optimised curve - green

interpolating linetransformed points

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Teeth Generation

The curve is then run through a teeth generation script to generate cut files. Each curve is assembled with 4 strand of teeth, they are to be cut with 4-axes CNC router or water jet cutter (in real scenario) out of thick timber.The negotiation between accuracy and tolerance is the key to successful fabrica-tion.

points for teeth

planes

Scripting

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Double LoopThe final form selected is one which is substantially strong and interconnects at sufficient points. Curvature is optimized such that it does not violate the maximum bending capability. It has four asymmetrical wings and a central atrium which can enclose various programmes.

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EnclosureThe rib structure is designed to be a frame that can receive different enclosure depending on the programme desired. Lightweight membrane with wire stiffener can be used to partially or completely enclose the structure.

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Documents

Portfolio Year 3 - Semester 1