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Rapidly Deployed and Assembled
Tensegrity System
Phillip Anzalone
New York City College of
Technology, CUNY
Stephanie Bayard
Pra Instute
Ralph S. Steenblik
New York City College of
Technology, CUNY
An Augmented Design Approach
ABSTRACT
The Rapidly Deployable and Assembled Tensegrity (RDAT) project enables the ecient automated
design and deployment of dierenal-geometry tensegrity structures through computaon-driven
design-to-installaon workow. RDAT employs the integraon of parametric and solid-modeling
methods with producon by streamlining computer numerically controlled manufacturing through
novel detailing and producon techniques to develop an ecient manufacturing and assembly
system. The RDAT project emerges from the Authors' research in academia and professional
pracce focusing on computaonally produced full-scale performave building systems and their
innovave uses in the building and construcon industry.
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INTRODUCTION
The Rapidly Deployable and Assembled Tensegrity (RDAT) system
developed from the authors' research focusing on the invenon
of computaonally produced performave full-scale building
systems and how they can have innovave uses in the building
and construcon industry (Anzalone 2014; Anzalone 2016).
Currently, RDAT research is at a stage of full-scale producon
of tensegrity masts and plates with variable geometric congu-
raons, including the necessary design, analysis and producon
workow (Clarke and Anzalone 2006). The goal of the RDAT
program is to enable rapid design and deployment of a wide
variety of dierenal-geometry tensegrity structures through an
augmented design process, engaging machine learning, auto-
maon and mixed-reality interfaces to produce a manufacturing
and installaon workow at the scale of architectural building
systems. The project incorporates the integraon of parametric
and solid-modeling methods to enable computer numerically
controlled (CNC) manufacturing of components and ecient
complex system assembly in the eld through innovave design
detailing and producon methods.
TENSEGRITY SYSTEMS IN ARCHITECTURE
The RDAT Program leverages the advantages of tensegrity
structures, coupling advances in science and technology
produced since their incepon. In 1975, Buckminster Fuller
coined the term tensegrity as a conjuncon of tension and
integrity (Fuller 1975). The term describes a structural system
of compressive and tension members that yield mechanical
equilibrium. More recently, Pinaud, Masic and Skelton precisely
state that tensegrity structures are a set of disconnuous
compressive components interacng with a set of connuous
tensile components to dene a stable volume in space (2003).
Contemporary research in tensegrity has expanded to include
biological systems such as bone and tendon conguraons,
as the study of forces and indeterminate structures through
computaonal analysis has expanded the science considerably.
Although contemporary architects and designers now have
access to computaonal tools with potenal to solve the
indeterminate forces associated with tensegrity structures, very
few tensegrity systems are developed within the architecture
profession due to some of the inherent features of the struc-
tures. The systems tend to be dicult to precisely form, have
exibility under load beyond normave architectural structures,
and require materials and detailing beyond normal possibility in
building condions. Renewed interest in deployable structural
systems, cable façade systems, and fabric tensile structures
demonstrates the need for an interface architects can use
to eciently develop tensegrity designs prior to compleng
the cumbersome calculaons tradionally associated with
indeterminate form-nding. For example, Kenneth Snelson’s
tensegrity sculptures are the embodiment of the Fuller and
Pinaud et.al. denions of tensegrity (Zhang, Oshaki, and Kanno
2006). His methodology is based upon physical model building,
numerous measurements, and iterave renement of tension
cable lengths on the nal unique piece. Research completed
at the Max Planck Instute for Intelligent Systems in Stugart
states an analycal form-nding method exists requiring the
designer to predene the cable length but then calculates the
rao directly without involving the iterave process (Bugartz
2007). Contemporary computaonal tools can be harnessed to
bring about a more ecient integraon of digital and physical
producon in the creaon of indeterminate structures.
Tensegrity structures have numerous advantageous properes.
As three-dimensional self-stressing cable systems, they have a
relavely small number of disjoint compression members (Figure
1). They are self-erecng, as tensioning the nal cable trans-
forms them from a compact loose network of members into a
large three-dimensional volume. As such, tensegrity systems
are extremely lightweight, materially ecient, embody resilient
properes, allow system exibility, and are composed of primarily
standardized linear elements. In addion, through the RDAT
System, they are now calculable, easy to assemble and recon-
gurable, oering potenal uses as structural reinforcement,
infrastructural elements, reusable or le-in-place formwork,
scaolding, and other building construcon elements as well as
1 Tensegrity structures - disjoint compression members systems.
94
the well-understood use as exible building components such as
roofs, curtain-walls and other similar systems (Oppenheim and
Williams 1997).
APPLIED COMPUTATIONAL TENSEGRITY
SYSTEMS
Contemporary computaonal tools can be harnessed to bring
about a more ecient integraon of digital and physical produc-
on in the creaon of indeterminate structures. If parametric
design (and it's associated byproduct Building Integrated
Modeling) dened digital producon in Architecture the rst two
decades of the twenty-rst century, augmented design intelli-
gence will dene the designer's way of working for at least the
next two. The second machine age is upon us, ushering in “the
automaon of knowledge work" (Brynjolfsson and McAfee 2016),
which will again transform the designer's process akin to the
transformaons brought on by the personal computer at the end
of the last millennium.
Inspired by Vannevar Bush's "As We Make" (1945), outlining a
way of working collaboravely with computers, Doug Engelbart
published "Augmenng Human Intellect: A Conceptual
Framework" (1962). This history is important for spelling out
a method and the idea of co-authoring, or collaboraon, with
computaonal systems in the process of creaon. Jumping ahead,
more specically: "To design is to generate and to choose" (Mitra
et al. 2016). Parametric design is based in using algorithms to
generate versions. In early 2010 David Ruen gave an intro-
ductory lecture at the Architectural Associaon in London on
his Galapagos solver for Grasshopper, taking algorithmic design
to an intelligent next level, allowing designers to construct an
algorithm and set tness parameters for which the computer can
test soluons to nd the best t.
Where parametric modeling allows for a streamlined workow
for version matrices, the use of an augmented design intelligent
solver allows for an intelligent version matrix where all possible
outcomes are considered for tness. This creates a much more
robust process that supplements the intuion of the designer
with soluons which may have been overlooked or not consid-
ered otherwise.1 As stated by David Copps at MIT's EmTech,
augmented intelligence requires three components: a machine
learning environment, a user experience, and human curaon
(2016).
Using recent developments in machine learning as a part of the
design process opens extensive opportunies for developing
prototype versioning, so the designer may realiscally tease out
and analyze innumerable possible conguraons. This allows for
comprehensive near real-me analysis of a greater set of possible
parametric examples. The research team believes that this
technique will aid in the discovery of unrealized conguraons
potenally with unforeseen benets or applicaons. Addionally,
incorporang sensors into the assembly allows for an automa-
cally actuated or responsive system that can be deployed as part
of the structure. This will lead to analycal feedback into the
machine learning parameters for applicaon to future cong-
uraons, and opmal techniques for real-me environmental
interacon.
Rapidly Deployed and Assembled Tensegrity System Anzalone, Bayard, Steenblik
2 CATIA and Grasshopper soluons inform the RDAT System.
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There is an opportunity to use new and novel tools such as the
OpenAI Gym project, used to develop and test reinforcement
learning (RL) algorithms or agents. Some of the environments
lend themselves to use with the development of dynamic
structures; in essence, they allow an RL agent to explore cong-
uraons without preconcepon. This method is similar to current
computaonal geometry tools in that it allows the designer to
evaluate more iteraons, but it takes the logic one step further
because the RL agent uses four values to inform the iterave
learning process, observaon, reward, info, and done (used to
reset the environment for another iterave experiment)
This logic is based on a tried and tested "agent-environment
loop". Each me step, the agent chooses an acon, and the
environment returns an observaon and a reward. The RL
agents start with random acons and then, through the feed-
back provided by the iterave learning process, the RL agent is
encouraged to make increasingly informed decisions over me.
Current experiments have not been directed toward spaal
or architectural problems, but the preliminary exercises show
promise for their applicaon toward dynamic structural systems.
Another recent development which feeds the augmented design
approach is "Deep Reinforcement Learning for Tensegrity Robot
Locomoon" (Zhang 2017). This project uses mirror descent
guided policy search (MDGPS) as a means of accomplishing
tensegrity locomoon. The replicaon and adaptaon of both of
these learning systems will enhance the RDAT’s augmented deci-
sion-making process through the use of computaonal learning
systems.
RDAT COMPONENT AND SYSTEM DESIGN
As a design methodology, the RDAT System integrates these
properes into digital design tools, a detailed and customized set
of physical components, and digital fabricaon technologies to
create a cohesive system, migang the interoperability issues
associated with exisng cross-plaorm design, analysis, fabri-
caon and project delivery methods. The goal is to develop an
opmized, project-dependent workow, coupled with intelligent
building components, to resolve interoperability conicts by
adapng exisng soluons and proposing innovave alternaves.
Since the late 1980s, architects and engineers have used
computer-aided design and manufacturing (CAD/CAM) tools
to develop building projects while narrowing the gap between
representaon and fabricaon. Researchers have argued that
advances in digital design and fabricaon have led to a triumph
of appearance over substance and that few truly new materials,
features and processes have resulted from the proliferaon of
digital design techniques. Furthermore, the reliance of architects
on crasmen and fabricators to carry out their designs suggests
that architects are disconnected from the skill of making.
Research on the use of digital design tools (CAD/CAM, BIM,
scripng and computaonal analysis), project delivery methods,
and fabricaon technologies in order to synthesize full-scale case
study projects, lead to new proposals to develop the use of inno-
vave materials, novel processes and ulmately to reintroduce
making to architects as an integral component of digital design
and fabricaon (Atelier Architecture 64 n.d.).
Prototyping done within the framework of exisng soware
is a crical method for rapidly developing a set of processes
for tesng while simultaneously developing the criteria for the
eventual custom design and analysis tools that the authors
are currently programming. Using CATIA Generave Shape
Design and CATIA Knowledge Paerns combined with Rhino
and Grasshopper studies, the RDAT System concludes with the
fabricaon of a tensegrity tower derived from designs param-
eterized in the computaonal system through a customized
program interface (Figure 2). The digital and associated physical
fabricated components address pre-stressing or post-stretching
of the tension elements during the assembly process as well
as assembly tolerances, while also tracking each category of
element for opmizing strength, assembly sequence and inven-
tory (Figure 3).
The RDAT node detail was developed to allow for variable
parametric assembly processing with the ability to be quickly
deployed, demounted and reassembled for numerous tension
line conguraons. Addionally, the node is simple to construct,
as strong as tradional tensegrity connecon methods, ecient
3 RDAT node detail.
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and elegant (Figure 4). The fundamental process relies on the
inherent compressive forces on the strut at the node detail from
the combina on of three acute angle tension wires and one
obtuse angle wire. At each node, the three-dimensional vectors
combine to a resultant vector which is always directed into the
node, thus preven ng the separa on of node and strut. This
allows for rota on to relieve internal stresses from system exing,
and struts easily engage and disengage during assembly and
demoun ng of the structure.
The RDAT system node is fundamentally composed of a cylinder
of material that is machined to t within the strut. In the case
study, fabricated high-density polyurethane foam was used
to prototype the cylinders to t snugly within the anodized
aluminum tubes. CNC equipment was used to tap a thread into
the center of the cylinder for the a achment of the connec on
disk. The connec on disk is a disk of plasma-cut steel that can be
bolted to the cylinder as well as connected to the four tension
lines at the node. The cu ng of the disk is detailed to allow for
tolerance at the tension connec ons; the load is transferred
to the disk and strut simultaneously for seamless force- ow
through the system.
Once all elements are produced using extracted computer
model data, the process for assembling a completed tensegrity
prism is 1) construc on of nodes, 2) assembly of an end-prism,
and 3) a achment of the remaining prism elements linearly to
the end-prism (Figure 5). Once constructed horizontally, the
Rapidly Deployed and Assembled Tensegrity System Anzalone, Bayard, Steenblik
4 Parametric assembly with rapid, demounted and reassembled.
5 Tensegrity prism assembling is node construc on, end-prism assembly, and linear a achment of end-prisms.
6 Lightweight structure can be re-posi oned by one or two people.
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Case Study 1: Urban Forest, Montpelier, France, 2010
The Urban Forest installaon was constructed for the Seventh
Annual Fesval des Architectures Vives exhibion in Montpelier
France in 2012. It served as a test for rapid deployment of a
full-scale system due to the requirements of erecon within one
night. The structures are three six-meter-tall conical tensegrity
towers of anodized aluminum compression members and stain-
less-steel tension members (Figure 8). Installed in the Hotel de
Griy courtyard in Montpelier, the towers suspend a network of
metallic mylar dichroic “leaves”, reecng and colorizing sunlight
to the inhabited space below (Figure 9). The modied 5-prism
tower structure features an innovave nodal design allowing
rapid deployment and compact storage measuring 2 m long and
50 cm in diameter.
structure is lightweight enough to be posioned vercally by
one or two people, depending on the height of the complete
structure (Figure 6). If the structure is to be demounted and
transported, the procedure is reversed; place the assembly in a
horizontal posion and 1) remove the primary tensioning cable
at one end-prism, 2) collapse the end-prism, 3) remove one
cable from the adjacent prism, collapsing the prism, repeang
step three unl all prisms are collapsed, and then bind and fold
each set of rods on the others unl a single package of rods
and cables is collected and bound together (Figure 7). While
assembly is longer in duraon than disassembly, a ve-prism
structure such as the case-study has been assembled in as lile
as one hour.
RDAT SYSTEM STUDIES
Producon of a tensegrity structure, fabricaon, assembly
and installaon, has historically been the site of trial-and-error
methods as described above. The RDAT system integrates
the design, analysis, fabricaon and assembly of the system
through developments based on the authors' previous work in
advanced networked structural systems. A crical aspect of the
development of a seamless workow is the step between the
computaonal form-nding and analysis and the manufacturing
of the components for physical construcon. The creaon of a
detail that is designed from its incepon to conform to the algo-
rithms and parameters that are incorporated into the soware
including geometry, material properes, degrees of freedom
and other aspects of the system is essenal to assure that the
produced components have the capacity to perform as designed.
Simultaneously, a feedback loop is put in place to allow develop-
ments during prototyping, case studies and physical tesng to
integrate results into the programming of the CAD/CAE system,
ensuring that the computaonal component conforms to the
producon component. Through a series of case studies where
building scale producon is realized, the system can be tested
against performave and producon criteria.
7
9
8
98
Urban Forest is a prototype for digitally fabricated tensegrity
structures in the form of self-supporng towers and a means to
demonstrate and test the structural strength as well as its formal
capacies. Urban Forest is an inial prototype driven by ideas in
the greater context of potenal architectural applicaons, such
as eciency in materials, structural strength, and other technical
benets. Tensegrity presents a system that is easily transportable,
collapsible, and has the potenal to create large walls, enclosures,
structures with minimal amount of materials.
The Urban Forest case study was used to test the ability to
prefabricate the components in place within the structural
conguraon, collapse the structure for shipping, and redeploy
with a minimal of me and labor required. This project was
erected in France by one person over the course of an evening,
proving that the design concept was sound while revealing
potenals for improvement in the design and detailing that were
added to later iteraons.
Case Study 2: Salford Meadows Tensegrity Bridge
Competition,2013
The Tensegrity Bridge entry for the Salford Meadows Bridge
Compeon seeks to provide a needed link between Salford
Meadows and the surrounding community, while simultaneously
promong an ecient and funconal structure and celebrang
the future potenal of Manchester (Figure 10). With a nod to
the rich industrial past of the local community, the innovave
tensegrity structure proposed reinforces the dynamic nature of
the nearby Engineering Faculty of the University of Salford and
develops a catalyst for encouraging future growth (Figure 11).
The importance of the local community demands a world-class
structure as a response to the development of the city.
Tensegrity Bridge was developed through an in-house computa-
onal program to streamline the design, analysis and producon
of a tensegrity system through parametric solid-modeling and
computaonal physics simulaons, allowing for the formulaon
of a sinuous shape that weaves the cable supports around a
direct linear pathway (Figure 12). The design strategy develops
the potenal of Salford Meadows by creang a link and aracng
new visitors, while expressing the bridge as a landmark through
the highly visible conguraons at the landings of the bridge. The
system is engineered to take advantage of the forces developed
in a pedestrian bridge of this scale through computaonal sizing
and conguraon of the elements and the tensegrity form.
The structure is naturally resilient and self-tunes to develop
counter-vibraon, dampening movement due to passage of
pedestrians. Suspension supports for the footbridge, connected
with an isolang detail, reduce vibraons by dispersing the forces
in the naturally resilient tensegrity system. The lightness of the
structure reduces the need for extensive foundaons at the
embankment so that support can be focused primarily on two
point loads above the river, providing a less invasive grounding
condion and simultaneously expressing the gracefulness of the
proposal.
10 Salford Meadows Bridge Compeon entry.
13 Parametric physics simulaons, enable the sinuous shape.
12 Parametric physics simulaons, enable the sinuous shape.
Rapidly Deployed and Assembled Tensegrity System Anzalone, Bayard, Steenblik
11 A nod to the community’s industrial past and academic connecon.
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This compeng entry allowed for the study of a full-scale
applicaon with the collaboraon of an engineer with extensive
specialty structures experse, including tensegrity structures,
Dr. Will Laufs. The authors were able to test the form-nding
and analysis of their computaonal format in response to the
program and the Engineer’s advice (Figure 13). Further rene-
ments in the algorithms used resulted from the applicaon of the
system at bridge scale.
CaseStudy3:AIACenterforArchitectureInstallation,New
York,NewYork,2014
The Towards a New Industry installaon quietly explores the
ambient possibilies of new industry, tensegrity systems, and
new media with an exhibion of projects and content related
to AECOM’s 2014 student compeon Urban SOS: Towards
a New Industry. Featuring video integrated in three tensegrity
sculptures, the exhibion curates the four nalist projects as well
as schemes from other program parcipants. The system is a
triad of self-supporng tensegrity towers where the placement
of the structures allows individuals to freely circulate around
each respecve tower, experiencing the layering of materials and
video projecon mul-topicly (Figure 14). The self-supporng
nature of tensegrity towers introduced a unique design and
fabricaon challenge. The formal quality of the sculptures along
with an intelligent use of materials required the collaboraon and
experse of various designers—this integrated design approach
is one which denes the success and spirit of the Urban SOS
program.
The Towards a New Industry installaon allowed the authors to
further rene the system to include adjustable detailing for eld
modicaons (Figure 15). The addion of relavely high-weight
projectors to the system on-site posed a challenge to the form-
nding algorithms that needed to have adjustment capabilies
once installed (Figure 16). A novel adjustable node and strut
system was added to accommodate on-site changes to the
system and loading condions, bringing the RDAT system closer
to the goal of an automacally actuated system.
CURRENT RESEARCH AND FUTURE
DIRECTIONS
Inial research parally addresses digital design and fabricaon
issues with tensegrity systems, but more importantly, exposes
the disconnect between ease of digital design and the reali-
es of construcng complex geometric systems. In parcular,
the tensegrity tool provides the designer with a workow that
adjusts the tensegrity structural system based upon user-inputs
while also generang the necessary fabricaon specicaons.
However, successful deployment of a tensegrity structure
remains in the execuon of the assembly methods used outside
of the digital design and digital fabricaon toolbox. Furthermore,
synthec biology research arms the need for physical tesng of
prototype composite materials in order to validate the compu-
taonal analysis. With the existence of an opmized digital
workow, eorts should be focused on developing an interface
for transioning digital design content into manufacturable
objects by adapng exisng fabricaon technologies or designing
new fabricaon soluons.
14 Integrated approach - input from various experse.
16 New challenges driver further innovaons. 17 Future developments.
15 Each installaon allows for addional renements.
100 Rapidly Deployed and Assembled Tensegrity System Anzalone, Bayard, Steenblik
The goal of future work is to contribute to the design, produc-
on and realizaon of innovave projects through connued
research in digital design and fabricaon technologies (Figure
17). Using recent developments in machine learning in the design
process opens extensive opportunies for development of proto-
type versioning in order for the designer to realiscally tease out
and analyze innumerable possible conguraons. This allows
for comprehensive real-me analysis of a greater set of possible
parametric soluons. The research team believes that this
technique will aid in the discovery of unrealized conguraons
potenally with unforeseen benets or applicaons. Addionally,
incorporang sensors into the assembly allows for an automa-
cally actuated or responsive system. Eventually, this may lead to
analycal feedback into the machine learning parameters applied
to future conguraons, and opmal techniques for interacon.
Current developments include generalizing the prism geometry
beyond three struts, expanding the mast structure into a planar
surface and incorporang actuated sensing and programmed
systems into the structure. Currently, the team has been
expanded to include interdisciplinary experse beyond architec-
ture to innovate in the computaonal algorithms and interface,
developing a recongurable MEMS joint and strut system that
will allow tuning and topology adapon (with the Mechanical
Engineering & Industrial Design Department) and a system to
research modes of automated assembly in on-site construc-
on condions (with the Civil Engineering & Construcon
Management Department). Future interdisciplinary research
trajectories include the incorporaon of energy generang and
storage strategies with a robocs industry partner as part of a
building integrated system.
ACKNOWLEDGMENTS
Research Assistants at GSAPP: Brigee Borders, Shaun Salisbury, Sissily
Harrell and Rebecca Riss
Research Assistants at aa64: Vida Chang, Brian Vallario and Ardavan
Arfaei
Collaborave Enes: LaufsED (Dr. Will Laufs), AECOM (Aidan Flaherty
(Project Manager), Travis Frankel, Tyler McMarn, Daniel Lee (Video
Producer) and Peter Zellner.), NYC AIA Center for Architecture, Mio
Guberinic, Costumer.
Fabricaon Team at GSAPP: Nathan Carter, Diego Rodriguez, Vahe
Markosian, Andrew Maier, Jacob Esoco, Michael Schissel, Maya Porath,
Eileen Chen, Michelle Mortensen, Michelle Ku, Arkadiusz Piegdon and
Zachary Maurer, Wade Coon, Taylor Burch
NOTES
1. IBM has recently released its quantum experience allowing research
iniaves to use it's quantum computer. The introducon of quantum
compung into the mix as we move toward more intelligent machines
creates expansive possibilies yet unknown to humanity. Concevibly
opening the door to soluon sets beyond the current comprehension
of humanity.
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IMAGE CREDITS
All drawings and images by the authors.
Phillip Anzalone is a Professor of Architectural Technology at NYC
College of Technology as well as a praccing Architect as Principal at
Atelier Architecture 64. Phillip’s research includes the applicaon of
science and technology to architectural design problems. Phillip is the
lead research and development faculty for the NYCCT Architecture
department’s Computer Numerically Controlled and Roboc Fabricaon
Laboratory. Phillip has a BPA Architecture from SUNY Bualo and a
MArch from Columbia University.
Stephanie Bayard is an Adjunct Associate Professor of Architecture
at Pra Instute, and a Principal at Atelier Architecture 64. Stephanie
previously worked for Bernard Tschumi Architects and internaon-
ally in Milan, Paris and New York. She has taught at Parsons The New
School for Design, Ohio State University and Rensselaer Polytechnic
Instute. Stephanie teaches design studios and housing seminars at Pra
Instutes's Graduate Architecture + Urban Design Program. Stephanie
received her Architecture Diploma with disncon from Paris La Villee,
France, and her MsAAD from Columbia University.
Ralph S. Steenblik is an adjunct professor at CUNY, has taught at Pra
Instute and NJIT, and has made signicant contribuons at mulple
renowned architecture oces, including Asymptote Architecture and Pelli
Clarke Pelli. Most recently his work was published in "Project Ancipaon"
2016, and he spoke at AIANY Design Conference 2016, and at an
UNESCO sponsored symposium on Ancipaon held in Trento, Italy. He
holds a masters from SCI-Arc.