FRATTARITHE STRUCTURAL FORM TOPOLOGY OPTIMIZATION IN ARCHITECTURE AND INDUSTRIAL DESIGN

LUCA FRATTARI

THE STRUCTURAL FORMTOPOLOGY OPTIMIZATION IN ARCHITECTURE AND INDUSTRIAL DESIGN

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University of CamerinoSchool Of Advanced Studies SAS

School of Architecture and Design “Eduardo Vittoria”Ascoli Piceno - Italy

Ph.D. in:Architecture, Environment and Design

Curriculum:Industrial Design and Experimental Architecture - IDEA

Cycle:XXIII°

THE STRUCTURAL FORMTopology Optimization in Architecture and Industrial Design

Conceptual design of a pedestrian bridge by means of topology optimization

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This research stems from the requirement to explore the capability of structural optimization in the architectural and industrial design field.

In the last decades, special tailoring of software has been tried out, mainly to applications fields such as aeronautics but without integrating the aesthetic \structural aspects of the design.

preface

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The application of Topology Optimization in Architecture has allowed to obtain the organic shape of the bridge shown in the picture.

preface

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1 INTRODUCTION1.1 The Structural Form 1.2 The egg, the seashell and the bone1.3 Apply lessons from nature

2 STRUCTURAL OPTIMIZATION 2.1 Optimization problem

3 TOPOLOGY OPTIMIZATION IN ARCHITECTURE3.1 Case studies in architecture3.2 Shelter 3.3 Stadium3.4 PEGASUS BRIDGE

4 FINAL REMARKS 4.1 Obtained results4.2 Future developments

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U

NTRODU

INTR

INTRODUCTION

UUINTRODDUCTIONINTROD

structural form

lessons from nature

development of biological structure

research goals

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the structural form

For contemporary architects integration between form and structure not always represents a design theme.

On the contrary, in nature, the two concepts are definitely inseparable because they are fuse together by the evolutionary processes of biological forms.

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For example, the capability of a tree to withstand self-weight is basic for itssurvival, as well as its strength against wind and other natural hazards.

the structural form1

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The trunk of a tree and its various branches may be compared to clamped rods, the Stuttgart airport has adopted a similar approach that allows the structure to grow guaranteeing its stability.

the structural form1

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The Egg is an efficient example of shell structures.

Thickness of few tenth of a millimetre is sufficient to withstand important loads if the material is placed correctly.

A similar concept is shown in the concrete shell by Heinz Isler in Switzerland.

1the egg

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1the seashell

The ribbing of the seashell maximizes stiffness and strength maintaining lightweight in the minimum volume.

The same principle is applied in Architecture to build fascinating vaults or components such corrugated irons.

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1the bone

Bones are another fantastic example of natural optimization.

Bone growth is surprising and attractive, the mass is concentrated according to the stress distribution descending from external loads.

This process is even reversible as observed on astronauts that lose bone mass after a long stay in a no-gravity ambient.

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1Apply Lessons from NATURE

In some cases, architecture draws strength from the line of thrust, surprisingly similar to natural lifeforms.

Some modern architects have practised such concepts.

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Among all, the Antoni Gaudì vision is remarkable.He made the Structural Form one of his distinguishing traits.

The Sagrada Familia and Parco Guell in Barcelona are universally deemed to be masterpieces, they stem from studies carried out empirically, but in an absolutely genial way.

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Todays, designers have enhanced tools that allow continuing this exciting research.

The topology optimization, seems to be the tool that better simulates natural growth.

We might say: “Nature can give lessons to the architects again”.

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CTU

STRUCT

STRSTRUCTURAL OPTIM

IZATION

RRSTRUCTUS URAL OPTIMIZATISTRUCTU

Optimization problem

Objective function, design variables,

design constraints and design space

Optimization techniques

Overview on the topology optim

ization

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2Optimization problem

An optimization problem consists of minimizing or maximizing a given function while satisfying suitable constraints.

Structural optimization decreases the structural weight increasing the strength,

or decreases the weight of an existing structure maintaining the same stiffness features.

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Simplifyng, a designer needs:

Design Space (2D or 3D)RestraintsObjective function (weight - strength)

Optimization problem2

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OG

OPOLOG

TOPOTOPOLOGY OPTIM

IZATION IN ARCHITECTURE

AAOGY OPTIMIZGY ZAOO TION IN ARCHITURET EETOGY OPTIMIZOGY OPTIMIZGYGY ZAZAOOOO

design tools

preliminary test

design methodology

case studies in architecture

discussions

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3Case studies in Architecture

Bridge design: Pegasus

Stadium design:Coliseum & Colossus

Shelter design:The harbour of Giulianova

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3The shelter in the harbour of Giulianova

The Gull’s wing design space of the shelter takes inspiration from the Natural Environment.

Some data:Length: 113 m - height: 6 m Covered surface: 2200 mqMaterial: steelLoads: Self weight, Snow, WindRestraints: Columns, Strength

Non-design space

Design space

Restraints

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The FEM model and key iterations of topology optimization analysis

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Results of the topology optimization analysis is represented by:

2 Isolated columns with five and three branches (right) 2 Columns connected by a connection beam

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The re-design shows an evolution from a:

solid model

to an STL model

to a network model

to a surface model

underlining the key role of the designer in

the project refinement.

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Size Optimization analysis has been use on the latticed steel structure.

A tentative pre-design of the structure suggests the use of pipes and bars with

the following size for ribs, chords and ties:

ribs > pipes d = 193.7 mm and t = 16 mm

chords > pipes d = 244.5 mm and t = 25 mm

ties > bars d = 30 mm.

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Size optimization procedure needed only three steps to get 30% weight

reduction.

The maximum stresses in steel sections were lower than 150 MPa.

Initial weight 441 tons

Final weight 308 tons.

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Considerations

Weaknesses: Cost of the structure and needs of a facade.

Potentials: Fascinating Structural Form and impressive material reduction

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3Coliseum: the concept stadium

solidThinking Inspired has been used

to develop the stadium exploiting its

conceptual design features.

Coliseum is an elliptical stadium of 120m x

140m long and 30 m high.

Images show the key steps of the re-design

process

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3The key role of the designer

This experience underline

the central role of the designer.

From one inspiration the designer

can create three different

interpretations

A single design space for three

different styles

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3Coliseum

1st interpretation, Coliseum in concrete

This interpretation exploits the

topological concept.

The designer draws inspiration on how

and where to place the structure.30

3Coliseum

The designer has the key to define the

overall aspect of the concept following

his creativity.

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3Coliseum

2nd interpretation, Coliseum in steel

This interpretation exploits the same approach

(topological concept) combining commercial steel

profiles for the structural elements.

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3Colossus: the heir of Coliseum

A second way to apply topology optimization in architecture is to exploit its

expressive potential with a literal re-design .

Thanks to this strategy we have a new organic-like stadium: Colossus.

This approach is very interesting because it pushes architects and engineers

to find different technologies to turn their concepts in reality.

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3Colossus: the heir of Coliseum

The columns of Colossus, have been

re-designed adopting different styles.

The designer , following the structural

suggestions can express its creativity

refining each detail of the project.

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3Pegasus: the bridge on Big Beaver Road

PEGASUS is the pedestrian bridge

designed to cross Big Beaver Road in

Troy.

PEGASUS is 50m long and will

connect Altair’s headquarters to the

services across the road.

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In this project we have some innovations in the method:

Pre-design of the steel deck

Loads are transmitted by pucks

Application of Topology Optimization and Size Optimization to obtain a structural skin \ collaborative skin.

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The columns are defined by:

Symmetrical Design space X and Y

Void areas are placed to force the

optimization to external and visible

sides

Loads are steel-deck self-weight,

crowd and wind.

Restraints are applied on the 3

columns

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The shelter is defined by:

Symmetrical Design space X and Y

Load is the wind

Restraints are applied on the connections

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ID

part

123456

Initial

thickness (mm)

150150150150150150

Final

thickness (mm)

13013013013011580


A size optimization of the columns has been

used once the re-design phase was completed.

Structure is subdivided in 6 sectors with the same

initial thickness.

Thanks to size optimization the weight decreased

of 16% (from 453 t to 380 t).

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Pegasus is the first example of an optimized hollow structure with a collaborative

skin.

- The next slides are probably the most important of this project cause they

represent the visual communication of the project -

- They are the result of several sketches, studies and deep reflections on the

application of topology optimization in architecture -

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PEGASUS final re-design.

The bridge is composed of two main structures the shelter and the columns.

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PEGASUS final re-design.

The designer expresses his potential following the structural suggestions.

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Interior view:The deck has been changed to

have a nice view of the support structure.

Top view:Holes in the shelter guarantee the right sunlight illumination.

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PEGASUS is the complete combination of architect and engineer knowledge

and taste in matter of “Transparency and light”.

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3Pegasus

“Bright” ideasPegasus has been conceived to use LED technologies to emphasize the streamlines and to underline its lightness.

[Honestly because I love the movie TRON LEGACY...]

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3Pegasus

Light and “enlightened”

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3Pegasus

Weaknesses:

Special construction techniques are required such as naval and aeronautic.

High construction costs. 47

3Pegasus

Potentials:

Impressive organic-like language

Innovation in size optimization application

First example of an optimized structural skin 48

SREMARK

FINAL R

FIN

FINAL REMARKS

considerations about the obtained results

the structural form in light of the present w

ork

future developments

LFINALARKSAR SSA FINAFINAL

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DESIGN SPACEcreationdesigner

RE-DESIGN &CHOSE OF MATERIAL

TOPOLOGYOPTIMIZATIONsoftware / code

SECTION DATABASEcreationdesigner

ANALISYS MODELFOR SIZE OPTIMIZATION

designer

SIZEOPTIMIZATIONsoftware / code

FURTHER VERIFIESsoftware / code

STRUCTURECOMPLETE

is the resultsatisfactory?



yes

no

yes

no

yes

no

yes

no

yes

no

yes

no


is the

result depend

by section database

?

5Obtained results

An innovative design methodology to create Structural Forms

Brown boxes represent key phases of the design process.

Integration of: CAD CAE CAM

Interactive Display

Rapid Prototyping

Digital Fabrication

to create Structural Forms

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5Future developments

CAE + CAD = CAEDComputer Aided Engineered Design

Integration between CAE and CAD tools in the same environment

Rapid Manufacturing and Mass Customization to transform the industrial process in digital fabrication Visual Interactive Tools andReal 3d Interactive Display

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ACKNOWLEDGMENTS

Tutor and consultants:

Prof. GRAZIANO LEONI (Unicam Board)

Mech. Eng. JAMES P. DAGG (solidThinking)

Dr. JONATHAN JAGLOM (Objet Geometries)

Mech. Eng. ROBERTO D’ARIA (Altair Engineering)

Mech. Eng. ROBERTO VADORI (Motorola)

Dr. ANNE HUESER (Wacom Europe)

The author is kindly grateful for technical support to:

Altair EngineeringsolidThinkingObjet GeometriesWacomOvermachnetFabb ZCorp Eidolab 52

LUCA FRATTARI

THE STRUCTURAL FORMTOPOLOGY OPTIMIZATION IN ARCHITECTURE AND INDUSTRIAL DESIGN

Thank you for your attention

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FRATTARITHE STRUCTURAL FORM TOPOLOGY OPTIMIZATION IN ARCHITECTURE AND INDUSTRIAL DESIGN