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Fabricating Stereotomy - Variable moulds for cast voussoirs
... A previous tested model was used for its practicality in terms of number of voussoirs (9) and geometric variability (4 and 5 sided blocks) ( Figure 3). Specifics on the design strategy for this threelegged arch are described in a previous paper (Azambuja Varela and Sousa 2017), where compatibility with the planar contact faces mold is introduced. Following the scale adjustment of the vault, a parametric definition generates automatically the different mold configurations, various rearrangements of the same reusable elements (Figure 4). ...
Mass customizing of building components allows new conditions to explore aesthetic and sustainability in architecture. However, such possibilities tend to require the use of expensive and heavy digital fabrication machinery, which is seldomly available in most regions on the planet. In this context, this paper presents a research in progress that explores Augmented Reality (AR) to support craft production of customized stereotomic components. As a portable technology, the work examines the potential of AR to materialize design solutions that are geometrically complex and variable. Considering the current research on augmented fabrication processes, this work contributes to producing variable building components for stereotomic construction with a focus on earth-based materials. Extending the findings of a recently completed PhD thesis, the work replaces the use of a robot with the HoloLens glasses and Fologram application to produce low-cost and reusable molds. This augmented fabrication setup allows the human control of the production of variable molds, ready for casting and assembly of stereotomic components. This work addresses several of the NEB and UN SDGs goals.
L’obiettivo della ricerca è quello di definire le nuove frontiere dell’architettura in pietra. Tale obiettivo è perseguito secondo due modalità: una teorico-critica e una sperimentale/operativa. La tesi fornisce dunque un’ampia trattazione dei temi storico-critici connessi alla recente riscoperta dei materiali lapidei da parte del mondo della progettazione. Gli stessi temi sono alla base delle riflessioni concettuali e operative che hanno portato alla definizione di inedite strategie progettuali e costruttive volte alla realizzazione di alcuni prototipi sperimentali presentati nella tesi. Questi prototipi hanno il ruolo di dimostrare nuove possibili strade che possono portare in un prossimo futuro alla ridefinizione del ruolo dell’architettura in pietra all’interno della disciplina architettonica. Le nuove frontiere proposte presuppongono l’utilizzo dei più recenti strumenti di progettazione parametrico-computazionale, di fabbricazione digitale e robotica.
This research investigates the assembly of funicular shell structures using a single layer of flat ceramic tiles. The objective is to synthesize recent advances in structural prediction software with existing means and methods of on-site assembly. The primary area of investigation is at the scale of the tectonic unit-most specifically how introduction of geometric intelligence at the scale of the unit can simplify the assembly of forms that are difficult to realize in the context of modern construction. The project simulates an industrial production scenario in which components for a given shell structure can be fabricated using a wire cutter-equipped 6-axis robotic arm. It aims to increase the adaptability and applicability of ceramic shell structures.
The present study explores the possibility of tying up again the broken thread of research on stonecutting construction following in the wake of the discontinued weave of stereotomic culture, aiming at applying its innate creative momentum to the education of engineers and architects and to contemporary architecture.
Stereotomy is usually regarded as a classic discipline in the field of architecture which has lost its relevance to other construction methods. Recently we have witnessed approaches to the stereotomic way of building using modern digital technologies, bringing the discipline to the present. On the other hand, the complex shaped buildings being built in the present seem to lack some kind of structure visible in classic stone architectures. A shift in construction methods must be attended to, with its metallic beams and concrete massifs. For an understanding of what remains the same and what changes from the classic literature, this paper tries to create analogies between contemporary architecture surfaces and the discrete stone structures of the past. To achieve this, a concept of stereotomy semantics is introduced, creating a different posture towards the problem of division of surface in architecture.
Addressing both architects and engineers, this dissertation presents a new framework for the form finding and design of fabrication geometry of discrete, funicular structures in the early design phase. Motivated by ongoing debates about digital architecture and funicular shell form finding, it introduces a new methodology for structurally-informed design of curved surface architecture through the use of geometrical rather than analytical or numerical representations of the relation between form, forces and fabrication. Based on Thrust Network Analysis (TNA), new algorithms are presented that enable an interactive exploration of novel funicular shapes, enriching the known formal vocabulary of shell architecture. Using TNA, the framework adopts the same advantages of techniques like graphic statics, providing an intuitive and educational approach to structural design that ranges from simple explorations to geometry-based optimisation techniques. Complementary to this structurally-informed design process, the work reflects on the latest building technologies while also revisiting historic construction techniques for stereotomic stone masonry and prefabricated concrete shells to develop efficient fabrication design strategies for discrete funicular structures. Based on architectural, structural and fabrication requirements, several tessellation approaches for given thrust surfaces are developed for the design of informed discretisation layouts of any funicular shape. The flexibility and feasibility of the form-finding framework is demonstrated in several case studies employing the new structural design tool RhinoVAULT, which implements the developed form-finding methods. The use of fabrication design strategies is discussed in a comprehensive case study that shows project-specific tessellation design variations and first fabrication results for a complex stone masonry shell.
Today, free-form parts are made in small production volume with time consuming methods and a significant amount of material waste. These methods include computer numerical control (CNC)-machining and the layered rapid prototyping techniques stereolithography apparatus (SLA), selective layer sintering (SLS), fused deposition modeling (FDM), 3D print, etc., which are well suited for smaller parts that are rich in detail. Variable geometry molds (VGMs) offer a different approach to small production volume. A die or mold can change shape between the castings, and parts with a different geometry can be made in the same mold. VGM is used in a multitude of applications such as sheet metal forming of parts for aircrafts, trains, and cranial prostheses. The present project focuses on VGM for free-form concrete facade elements, which, in contrast to previous VGM projects, uses a liquid raw material and involves the use of only a small amount of force. The present VGM process is based on the so-called reconfigurable pin-type tooling (RPT) principle. The geometric possibilities have been examined using a proof-of-concept RPT test mold. Sixty closely packed adjustable pin-elements with hemispherical tops and a square section of 43.3×43.3 mm2 create a dimpled surface that is evened out using an elastic interpolating layer. Castings with concrete and plaster are made on an elastic membrane that is sucked toward the pins using a vacuum. The shape of the cast elements and the mold surface have been measured and compared. The RPT test mold can produce a large variety of free-form geometric shapes. It is possible to make straight vertical surfaces and even horizontal surfaces with dimples of only 0.3 mm. Part details can be made down to the size of a pin with hole depths up to 65 mm and protrusions up to 19 mm. Repeatability is better than the measurement uncertainty. VGMs using the RPT principle can be used for making scale models of a range of free-form cast concrete façade elements. It is almost possible to remove the imprints from the pins by using the right interpolators, but the dimples could also be a visually attractive characteristic of the process that could be valued by architects. Large hole depths and smaller protrusions are possible.
Robotic Fabrication of Stone Assembly Details
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- Clifford Mcgee
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- M P Kaczynski
- Mcgee
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114-121