Fab(){ Clay ;} Starsk LaraSasa JokicNasim Fashmi{ digital tectonics }2011/2012DevelopersStarsk Lara Nasim Fashami Sasa JokicProfesorMarta Male-Alemany AssitentsJordi Portell Miquel Lloveras Santiago MartinIaaCBarcelona - Spain2011 - 2012All rights reserved2012FFab ab() { Clay ;} 4 5{FabClay} Reference {FabClay} ReferenceThe global need for housing includes millions of refugees and displaced persons - victims of natural disasters and wars. Iranian architect Nader Khalili be-lieves that this need can be addressed only by using the potential of earth construction.After extensive research into vernacular earth building methods in Iran, followed by detailed prototyping, he has developed the sandbag or superadobe system. . Pasta has focused on a design-system using an in-novative fabrication method for the construction of housing. Based on an on-site, layered manufacturing process using a paste-like material. Developed from the customisation of existing CNC technologies and incorporating CAD tools and scripting platforms, the research work was aimed at finding an equilibrium between materiality, design intent and fabrication processes.Contour Crafting (CC) is a layered fabrication technology developed by Dr. Behrokh Khoshnevis of the University of Southern California. Contour Crafting technology has great potential for automat-ing the construction of whole structures as well as sub-components. Using this process, a single house or a colony of houses, each with possibly a different design.Anish Kapoor became known in the 1980s for his geometric or biomorphic sculptures made using simple materials such as granite, limestone, marble, pigment and plaster.[12] These early sculptures are frequently simple, curved forms, usually monochro-matic and brightly coloured, using powder pigment to define and permeate the form. While making the pigment pieces, it occurred to me that they all form themselves out of each other. Jonathan KeepHaving for many years used computer software as a tool to explore form I am now developinh techniques to print pots directly from computer codeUnfold there is a new species of design, semi-industrial craft, and although the definition of craft often refers to work by hand, in this context it reflects a renewed interest in building knowledge through repetition and practice of a skilled trade using the aid of tools6{FabClay} Introduction {FabClay} IntroductionFabclayistheprojectthatdemonstratesthenewvisionofmakingarchitectural design and constructions, In terms of changing the logic of built from human as aconstructortomachine,regardingtonewaspectsoftechnologypossibilities. It has started from researches on traditional way of building with simple and ac-cessible materi- als and continued by expanding the connections between archi-tecture and new technology. Through digital design process we are able to make complex shapes by simple rules that are emerging from mechanic performance and materials possibility.Materials properties and its communication with machines will create the perfor-mance in which complex forms can be emerged, therefore exploring the behavior of material and its potentials give rise to develop prototypes in order to achieve architectural applications in vari- ation of species in terms of scale, form and func-tion.INTRODUTION{FabClay}8 9{FabClay} Thesis {FabClay} ThesisDeveloping robot world and its effects on different industries create new approach to architec- tural design and the technique of constructing.How to translate tra-ditionalbuildmethodstotheroboticsystemperformance,willresponsetonew structures generation. Material, robot and computer science, simulating the per-formanceinwhich,thecombinationofdigitalworldandnewarchitecturalcon-structing definition has been demonstrated.We can also consider the advantage of robotic performance in terms of continues printing, which has been generated by mathematical logics and allow new struc-tures to be achieved.Themainresearchquestionofthisprojectaddressesiswhatinnovativetech-niquesofdesign,constructionandmaterialscouldprospectivelybedeveloped and eventually applied to archi- tectural system. According to the history of clay constructions that has been recorded through the history of architectural build-ing, there is not only a plenty of knowledge but also an intelligence of profes- sional treatment with environment in terms of material usage in appropriate way.Digital tecton- ics focuses on material deposition techniques. The additive fabrication is about adding mate- rial by using a device that can produce digital shapes and cre-ate the shapes which cant been made by humans hands.The digital fabrications tools and technologies have the main challenge of trans-lating the com- puters (bits information) ideas to analog space (material atoms).Once those skills have been identified, needs to be equipped to transform them to digital platform.THESIS{FabClay}CLAY{ MATERIAL }WHYCLAY1 : 1 SCALE FABRICATIONNATURAL CYCLE ECONOMICAL SUSTAINABLEFABRICATIONARCHITECTURAL DESIGNDESIGN TROUGH CLAYLOWENERGY CONSUPTIONMINIMALTRANSPORTATION COSTLOWCONSTRUCTION PROCESS 2D DIMENSION TO 3D DIMENSIONCOMPATIBLE WITH OTHER MATERIALSNATURAL FORCES FORMFINDINGCONSTRUCTION RESISTANCE USER EXPERIENCECONSTANT REPRODUCIONWITHOUT ENVIROMENT POLUTIONLOCAL MATERIAL12 13{FabClay} Material {FabClay} MaterialWHYCLAY?.Claysareperhapstheoldestmaterialsfromwhichhumanshave manufactured various arti- facts. The making of fired bricks possibly started some 5,000 years ago and was most likely humankinds second earliest industry after agriculture. From architectural point of view clay is almost forgotten material in construction process espe- cially in the contemporary design. There are still many people who use soil to build houses, but only in region where this material is cheap and with-out knowledge of new materials. So if we can discuss about clay as potential new material in digital era in architecture, we cant forgot all historical experience and knowledge of the material, equal in the other filed, such as sculptur- ing, pharma-cy. Therefore, for us as researchers it was very important to learn from craftsmen and artist who are working with clay. From artist we learn what relation of material with material proportion and may technique of preparation of material, while from ancient crafting how to prepare material for big object and to be resident to envi-ronmental condition. From economic sustainable point of you, clay is very cheap and assessable mate-rial. First of all, time from deposit and treatment of clay for use is short and dont include too many peopleVERY DEGRADED SOIL STABLE SOIL DEGRADED SOIL14 15{FabClay} Material {FabClay} MaterialPRECIPITATIONTEMERATURETRANSPORT 10 TO > 1000 KMCLAY MINERAL FORMATION AND TRANS-PORTATION MECHANISMWEATHERING AND EROSION - DETRITAL CLAYTRANSPORTATION ILAGPOS-LATERITECOVERLENS LATERITICGRAVELGRAVELLYCOLLUVIUMGRAVELDURICRUSTCLAYZONE ANDSAPROLITEFRESHBEDROCKPRIMARY HALOORE DEPOSITFERRUGIOUSSAPROLITE16 17{FabClay} Material {FabClay} MaterialWHEREWECANFINDCLAY?.Claysaredividedintotwoclasses:residualclay, found in the place of origin, and transported clay, also known as sedimentary clay, removed from the place of origin by an agent of ero- sion and deposited in a new and possibly distant position. Residual clays are most commonly formed by sur-face weathering, which gives rise to clay in three waysby the chemical decom- position of rocks, such as granite, containing silica and alumina; by the solution of rocks, such as limestone, containing clayey impurities, which, being insoluble, are deposited as clay; and by the disintegration and solution of shale. One of the com-monest processes of clay formation is the chemical decomposition of feldspar.Below are Scanning Electron Microscope Pictures of KaoliniteIntestratified with Illite.http://www.smianalytical.co.za/clay-analysis.html18 19{FabClay} Material {FabClay} MaterialEach particle the clay is a crystalline plate with an hexagonal outline . The average diameter of this plate is one micron (one millionth of a meter), a size so small it can only be observed by a high power microscope. Other particles in the clay are as large as fifty microns and as small as one tenth micron in diameter. The thickness of the clay particle is about one tenth the diameter with the faces flat and smooth.In a batch of moist clay, the water forms thin films between the faces of the clay plates. These films are very thin, averaging six thousandths of a micron in thick-ness. Of course, the more wa- ter added to the clay mass, the thicker will be these films. A sort of equilibrium exists in the clay mass with the particles pulled together by attractive forces and at the same time held apart by the water films. Therefore the wetter the clay mass, the thicker will be the water films and the more easily the clay particles can be forced to move in relation to each other. This explains why a wet clay may be molded with less force than a dryer one.When a plastic clay dries, the following steps occur: (1) the water in the layers be-tween clay particles gradually diffuse to the surface where it evaporates until final-ly the particles touch each other and the shrinkage stops; (2) the remaining water in the pores then dries out with no further shrinkage; and (3) absorbed water on the particle surface disappears.NATURE OF CLAY{CLAY, viscosity and plasticity}PLASTICITYCOMPONENT RESULTLINE OFCLAYWITHOUT CRACKS[TORSION]PLASTIC1 ml=PLASTICITYALLOW THE PRESERVATION OF THE FORM OF CLAY4 EXAMPLEWATERCLAYPLASTIC20%80%1%3 EXAMPLEWATERCLAYPLASTIC15%85%1%SHAPE MATERIALSCLAY WATER LINE OFCLAYWITH CRACKS[TORSION]1000gr 350 ml+ =2 EXAMPLEWATERCLAYPLASTIC15%85%0%1 EXAMPLEWATERCLAYPLASTIC10%90%0%20 21{FabClay} Material {FabClay} Material VISCOSITY2 EXAMPLEWATERCLAYVISCOSITY4 EXAMPLEWATERCLAYVISCOSITY1 EXAMPLEWATERCLAYVISCOSITY3 EXAMPLEWATERCLAYVISCOSITYCLAY WATER SEDIMENTATIONCLAYAND WATERSEDIMENTATIONCLAYAND WATERMIXED MATERIALS1000gr 350 ml+ =CLAYAND WATERWITH VISCOSITYCOMPONENT RESULT VISCOSITY1 ml=SEMIENTACION PREVENTS THE CLAYAND CONTRIBUTE TO THE UNION OF ITS MOLECULES22 23{FabClay} Material {FabClay} Materialviscosity clay plastic waterrange1,00 ml 10,00gr 1,00 ml 1,50ml clay1000grwater 0,00mlplasticity 0,00mlviscosity 0,00ml2 }levelWATER CLAY[ CHEMICAL ] ASPECT SCALE BY1Kviscosity clay plastic water1,00 ml 10,00gr 1,00 ml 4,50ml clay1000grwater 0,00mlplasticity 0,00mlviscosity 0,00ml4 }level handsviscosity clay plastic watermachine 1,00 ml 10,00gr 1,00 ml 3,50ml clay1000grwater 0,00mlplasticity 0,00mlviscosity 0,00ml3 }levelmachineviscosity clay plastic water1,00 ml 10,00gr 1,00 ml 0,00 ml clay1000grwater 0,00mlplasticity 0,00mlviscosity 0,00ml0 }levelpowderviscosity clay plastic water1,00 ml 10,00gr 1,00 ml 0,50 ml clay1000grwater 0,00mlplasticity 0,00mlviscosity 0,00ml1 }levelhardviscosity clay plastic water1,00 ml 10,00gr 1,00 ml 5,50ml clay1000grwater 0,00mlplasticity 0,00mlviscosity 0,00ml5 }level liquid24 25{FabClay} Material {FabClay} MaterialOurfirstmaterialtestwasveryimportantinwaytoconfirmourknowledgeof chemical behav- ior of the clay. As we expected to have as much plasticity we tried to put as lees water as we can in order to save possibilities to shape our mixture. In the other words, clay particles should be big and very sticky, something as plastic shits with water between. After few tests we realized plasticity level can be reduced by small amount of special crushed stone. Plasticity regulator opens a lot of pos-sibilities to get good plasticity mixture, but also a lot of problem to control shape cracking even in the early phases. Therefore viscosity regulator is necessary to still save flexibility of clay objet.PREPARATION{CLAY}26 27{FabClay} Thesis {FabClay} ThesisSTEPSmeasuringcupwater250mlclayplasticviscosity1000gr1.00.gr1.00.grwater100mlputingwater in thematerial 3 stepmeasuringcupmixerclayplastic1000gr1.00.gr1.00.grwater250mlwater100mlputingwater and mixing5 stepviscositymixerclayplastic1000gr1.00.gr1.00.grwater250mlwater100mlmixingthe material15 min6 stepviscositymixerclayplastic1000gr1.00.gr1.00.grwater250mlwater100mlmixingthe material7 min4 stepTOOL MATERIALspoon measuringcupwater350mlclayplasticviscosity1000gr1.00.gr1.00.grmixingpowder material 2 stepbalancemeasure1 stepmeasuringcupclay plastic water viscosity1000gr 1.00.gr 350ml 1.00.gr29{FabClay} Materialviscosity clay plastic watermachine 1,00 ml 10,00gr 1,00 ml 3,50ml clay1000grwater 0,00mlplasticity 0,00mlviscosity 0,00ml3 }levelWATER CLAY[ CHEMICAL ] ASPECT SCALE BY1KmachineProcess of mixing clay30 31{FabClay} Material {FabClay} MaterialSMOKESTACKFIRE DOOR CRUSHED STONEFIREDOORCRUSHED STONEOVENSMOKESTACKRAKU OVENTEMPERATURE900 C (1,650 F)32 33{FabClay} Material {FabClay} MaterialRaku,is an oriental technic from the 16th century, it is believed to have been origi-nated in Coria but it prospered in Japan and has extended throughout the world, apparently thanks to the tea ceremony. The word Raku means happiness. It is a method of creating effects with colors and textures with enamels or simply with smoke, rapidly fired and cooled while still in the oven. The clay used for Raku must be prepared with a high percentage of sand or grog to resist rapid changes at the extreme temperatures. A good choice of the clay to be used will avoid the risk of breakage.The firing of the enamels is done in gas or wood fired kilns. The enamels and colors are fired be- tween 800 o and 1000 o C with rapid firing, reaching the right tem-perature in 15 to 30 minutes, then the kiln is opened and the pieces that are red withheataretakenout.Whenapieceistakenoutofthekilnanditisexposed totheair,itisput,forashortwhile,intoametalbucket,halffullofsandordry leaves, sufficient for the reduction of heat and smoke to penetrate into the piece and transform the colors, enhancing the crackled enamel due to the heat crash, which is quite common in this enamel technic. Next it is rapidly cooled down, for a short time in another bucket with water, washing out at the same time the smoke stuck to the enamel.RAKU OVEN{BAKE}Raku Ovenhttp://www.godfrieddols.nl/portfolio/potterie/34 35{FabClay} Material {FabClay} MaterialBesides the work done with classic enamel, brilliant and crackled, we also have the naked or lost enamel Raku technic, on which the engobe will not adapt itself to the holder making the enamel loose at the end of the process, and only the drawings produced by the smoke will re- main, which can be induced by chance (crackled) or by the work of the ceramist.Thereisalsothetechnicknownasmattcopper,thankstowhichwithanover loadedcopperenamelwemanagetogetamattfinishthankstothewidecolor variety which copper develops in a reducing atmosphere. The oven can be loaded from the top or at the front, although the most recommended is the one by which the body of the oven lifts, thanks to pulleys, and the pieces are left at the top easily workable. This procedure produces smoke, so it must be done in the open air. To get the pieces out of the oven you must use long pincers and protect yourself with spectacles and heat gloves.Arduinohttp://www.arduino.comROBOTIC{ MACHINE }www.rapdasa.org/index.php/about-additive-manufacturing39{FabClay} Material38{FabClay} MACHINEAdditive manufacturing is defined by ASTM as the process of joining materials to makeobjectsfrom3Dmodeldata,usuallylayeruponlayer,asopposedtosub-tractive manufacturing meth- odologies, such as traditional machining. Additive manufacturingisalsoknownasrapidpro-totyping,additivefabrication,layer manufacturing, freeform manufacturing and 3D printing. Additive Manufacturing isthusaprocesstomanufacturepartsrapidlybytakinga3Dmodelofapart, slicingthatmodelintothinlayersandthenbuildingthatpartlayer-by-layerina machine, choosing from a variety of materials. AM allows a user to print a physi-cal representation of any CAD model. Depending on the AM process used, the part can be manufactured in a range of materials and can be used in a number of ap-plications.The technology is historically known as Rapid Prototyping. This is due to the fact that prototyp- ing was the main use of the manufactured parts. The main advan-tages of the process were that prototypes could be manufactured with no tooling and with very short lead times (compared to conventional manufacturing technol-ogies). However, recent advances in the technology al- lows users to manufacture parts from real engineering materials such as Nylon, Polycarbonate, ABS and even metalssuchastitanium,aluminium,stainlesssteeletc.Theserecentadvances have allowed AM to be used as a production manufacturing process, rather than being only a prototyping tool.ADDITIVE MANUFACTURING PROCESS{DEPOSITION}DEPOSITION1 MACHINE CONTROL{ HORSE}2 NOZZLE EJECTING MOLTEN MATERIAL3 DEPOSITED MATERIAL 4 X,Y,Z {3D SPACE}40 41{FabClay} MACHINE {FabClay} MACHINE42 43{FabClay} Material {FabClay} MaterialRapid prototyping with clay is basically reflected trough machine and material be-havior with intention reach as much as possible digital control. In our case pres-sure of the air and nozzle gives us possibilities to extrude clay. The experiments on the first begging showed us great suc- cess in terms of digital control machine, but that was not case with material. Our experiments started to be very compli-cated and information form experiments are very carefully sorted and annualized. For example, one milliliter of water or faster movement of machine can change all results.BEHAVIOR OF THE MATERIAL IN THE NOZZEL {MACHINE}spoon pump potspoon1 STEPMIXEDMATERIAL2 STEPFILLINGMATERIALpump potspoon pump potspoon pump pot3 STEPPLUGGINGNOZZLED4 STEPNOZZLEDREADY44 45{FabClay} MACHINE {FabClay} MACHINEPUMP {AIR SYSTEM}AIR { IN }AIR { OUT }ELECTROVALVEAIR COMPRESSMATERIAL {CLAY}CONNECTION PVC50 mmPIPE ACRYLIC TRANSPARENT50 mmREDUCTION PVC50 mm - 30 mmREDUCTION PVC30 mm - 1/2METAL REDUCTION{FOR AIR} 1/2-3/4 METAL REDUCTION{FOR AIR}3/4-6 mmMETAL CONNECTION {FOR AIR} 1/2CAP PVC50 mm46 47{FabClay} MACHINE {FabClay} MACHINECANWEMAKEOUREXTRUDER?.Beforewestartedbuildourextruderforthe clayweknewthatitshouldbeveryresistedonthepressureoftheair.Asmost important parameter in extruding clay, air and cycle of the air are main parameter in design pump for extruding. In order to have fully control of the process means that pressure of the air should be automatically reduced according to layer proper-ties. For example, thickness of the extruded layer is directly related to pressure of the air. Electro valve has possibilities to reduce pressure of the air and control how long air is inside extruder, what is very important because amount of material in-side of the nozzle is not always same. All of experiments what we did with pressure and extruder are important because they are pro- ducing the main parameter and variables for machine-material control.14EXAMPLE1gr700ml100gr1gr2br10mm distance base10mm thickness19EXAMPLE1gr700ml100gr1gr2.5br10mm distance base15mm thickness18EXAMPLE1gr700ml100gr1gr2br30mm distance base5mm thickness17EXAMPLE1gr700ml100gr1gr2.5br15mm distance base5mm thickness16EXAMPLE1gr700ml100gr1gr2br15mm distance base5mm thickness15EXAMPLE1gr700ml100gr1gr2br10mm distance base50mm thickness13EXAMPLE1gr700ml100gr1gr2br10mm distance base5mm thicknessOPEN / CLOSED12EXAMPLE1gr700ml100gr1gr2br10mm distance base10mm thickness11EXAMPLE1gr700ml100gr1gr2br10mm distance base8mm thickness10EXAMPLE1gr700ml100gr1gr2br15mm distance base7mm thickness9EXAMPLE1gr700ml100gr1gr3br15mm distance base14mm thickness8EXAMPLE1gr700ml100gr1gr2br10mm distance base9mm thickness7EXAMPLE1gr700ml100gr1gr3br20mm distance base12mm thickness6EXAMPLE1gr700ml100gr1gr2br10mm distance base9mm thickness5EXAMPLE1gr700ml100gr1gr2.5br10mm distance base10mm thickness4 EXAMPLE1gr700ml100gr1gr2br20mm distance base8mm thickness3 EXAMPLE1gr700ml100gr1gr3br10mm distance base10mm thickness2 EXAMPLE1gr700ml100gr1gr4.5br10mm distance base24mm thickness1 EXAMPLE1gr700ml100gr1gr4br10mm distance base13mm thicknessEXAMPLES OF PRESSURE OF AIR WITH A LIQUID MATERIAL{AIR SYSTEM}48 49{FabClay} MACHINE {FabClay} MACHINE50 51{FabClay} MACHINE {FabClay} MACHINE52 53{FabClay} MACHINE {FabClay} MACHINEExperiments with digital deposit material control started on the 2D CNC machine, compressor,onecomputerandnozzle(pump).Extrudingtechniquewastaken from food industry where this pneumatic process is very common. The first aim in this part was to investigate differ- ent material result according to different ma-chine movement. Pressure and stroke of the air is contorted digitally with Arduino board with security manual valve. Starting from this part, this project tends to be independent unit ready to be used on wherever construction site and project chal-lenge as less people involve in process. Therefore, digital control of the machine is manly important for this project.NOZZLE{DEPOSIT MATERIAL CONTROL}54 55{FabClay} MACHINE {FabClay} MACHINECOMPRESSORARDUINOPUMP {MATERIAL CLAY}BUTTON { ON / OFF}PARTS OF THE PUMP SYSTEMMACHINESNOZZLEELECTROVALVE AIR PRESSUREA PARTCPARTDPARTCOMPRESSOROF 10brVALVE AIR OPEN/CLOSE 3/4VALVE PRESSURE 3/4PIPE 3/4PRESSURE CLOCK 3/4PUMPMETAL NOZZLEBPARTACRYLIC HOLDERARDUINOTRANSFORMERBUTTO ON/OFF56 57{FabClay} MACHINE {FabClay} MACHINE58 59{FabClay} MACHINE {FabClay} MACHINE60 61{FabClay} MACHINE {FabClay} MACHINEFirst part of digital control consisting of generating from or model in the CAD soft-waresuchasGrasshopper(www.grasshopper3d.com).Mathematicalalgorithm allowed us to produce form and in the same time translate code in the machine language. Processing (www.processing. com) one more coding platform is tool for hacking machine and platform to accept machine coordinate and execute them in physical machine movement.ForthesecondpartoftheprojectweusedKUKARobot,whoallowedusbigger form, as this ma- chine has bigger work range, and in the same time more control ofthespeedandallmachineprocess.WeusedGrasshopperforthegenerating from, G-Code, and in the same time driving machine.MACHINECON-TROL MATERIAL CONTROL {HORSE}COMPUTATIONAL BEHAVIOR TO DEVELOP G- CODE FOR EACH MACHINES{KUKA- SHOPBOT}defnition digital tectonis 201162 63{FabClay} Thesis {FabClay} ThesisEEEXAMPLE1gr700ml100gr1gr3br15mm distance basezy xA EXAMPLE1gr700ml100gr1gr3br15mm distance baseAzy xG-CODE {SHOPBOT} PROPERTIESBzy xBEXAMPLE1gr700ml100gr1gr3br15mm distance baseCzy xCEXAMPLE1gr700ml100gr1gr3br15mm distance baseDzy xDEXAMPLE1gr700ml100gr1gr3br15mm distance baseFzy xFEXAMPLE1gr700ml100gr1gr3br15mm distance base64 65{FabClay} MACHINE {FabClay} MACHINE66 67{FabClay} MACHINE {FabClay} MACHINECONTROL MACHINE {SHOPBOT}RESULT PERSPECTIVERESULT PERSPECTIVERESULT PLANTRESULT PLANTmaterial viscositymax3 mm2 brMATERIAL SECION MATERIAL BEHAVIOR G-CODE8mmmaterial viscositymax1.8 brMATERIAL SECION MATERIAL BEHAVIOR G-CODE68 69{FabClay} MACHINE {FabClay} MACHINE70 71{FabClay} MACHINE {FabClay} MACHINECONTROL MACHINE {SHOPBOT}RESULT PERSPECTIVERESULT PERSPECTIVERESULT PLANTRESULT PLANTmaterial viscositymax3 mm2 brMATERIAL SECION MATERIAL BEHAVIOR G-CODE3 mmmaterial viscositymax3 brMATERIAL SECION MATERIAL BEHAVIOR G-CODE72 73{FabClay} MACHINE {FabClay} MACHINEPERFORMACE MACHINE 0%PERFORMACE MACHINE 1%PERFORMACE MACHINE 20%PERFORMACE MACHINE 40%PERFORMACE MACHINE 60%PERFORMACE MACHINE 99%74 75{FabClay} MACHINE {FabClay} MACHINERESULT PLANTRESULT PLANTCONTROL MACHINE {SHOPBOT}RESULT PERSPECTIVERESULT PERSPECTIVEmaterial viscositymax3 mm4 brMATERIAL SECION MATERIAL BEHAVIOR G-CODE3 mmmaterial viscositymax1.5 brMATERIAL SECION MATERIAL BEHAVIOR G-CODE76 77{FabClay} MACHINE {FabClay} MACHINEPERFORMACE MACHINE 0%PERFORMACE MACHINE 1%PERFORMACE MACHINE 20%PERFORMACE MACHINE 40%PERFORMACE MACHINE 60%PERFORMACE MACHINE 99%78 79{FabClay} MACHINE {FabClay} MACHINECONTROL MACHINE {KUKA}RIGTH 90RESULT TOPRESULT FRONTRESULT PERSPECTIVEmaterial viscositymax2 mm3 brMATERIAL SECION MATERIAL BEHAVIOR G-CODEshrinkingTOPmaterial viscositymax2 mm3 brMATERIAL SECION MATERIAL BEHAVIOR G-CODEshrinkingTOPRESULT TOPRESULT FRONTRESULT PERSPECTIVERIGTH 7580 81{FabClay} MACHINE {FabClay} MACHINE82 83{FabClay} MACHINE {FabClay} MACHINERIGTH 60 RIGTH 58CONTROL MACHINE {KUKA}RESULT TOPRESULT FRONTRESULT PERSPECTIVERESULT TOPRESULT FRONTRESULT PERSPECTIVEFORCE OFGRAVITITYmaterial viscositymax2 mm3 brMATERIAL SECION MATERIAL BEHAVIOR G-CODEshrinkingTOPmaterial viscositymax2 mm3 brMATERIAL SECION MATERIAL BEHAVIOR G-CODEshrinkingTOP84 85{FabClay} MACHINE {FabClay} MACHINE86 87{FabClay} MACHINE {FabClay} MACHINERIGTH 80 RIGTH CURVATURERESULT TOPRESULT FRONTRESULT PERSPECTIVERESULT TOPRESULT FRONTRESULT PERSPECTIVECONTROL MACHINE {KUKA}material viscositymax2 mm3 brMATERIAL SECION MATERIAL BEHAVIOR G-CODEshrinkingTOPmaterial viscositymax2 mm3 brMATERIAL SECION MATERIAL BEHAVIOR G-CODEshrinkingTOP88 89{FabClay} Material {FabClay} Material90 91{FabClay} Material {FabClay} MaterialCONTROL MACHINE {KUKA}RIGTH RIGTH CURVATURERESULT TOPRESULT FRONTRESULT PERSPECTIVERESULT TOPRESULT FRONTRESULT PERSPECTIVEmaterial viscositymax2 mm3 brMATERIAL SECION MATERIAL BEHAVIOR G-CODEshrinkingTOPmaterial viscositymax2 mm3 brMATERIAL SECION MATERIAL BEHAVIOR G-CODEshrinkingTOPCURVATURE92 93{FabClay} Material {FabClay} Material94 95{FabClay} Material {FabClay} MaterialCONTROL MACHINE {KUKA}RIGTH CURVATURERESULT TOPRESULT FRONTFABRICATIONmaterial viscositymax2 mm3 brMATERIAL SECION MATERIAL BEHAVIOR G-CODEshrinkingTOP96 97{FabClay} MACHINE {FabClay} MACHINE98 99{FabClay} MACHINE {FabClay} MACHINE100 101{FabClay} MACHINE {FabClay} MACHINECONCLUSIONOFTHEMACHINE-MATERILAPROCESSWithfirstexperiment where we started to control extruding and movement machine we real- ized that pressure of the air, distance nozzle from extruded layer and properties of clay mix-turegiveusrulesaccordingwhichwecanconcludeisitexperimentsuccessor not. It is obvious that all of these parameters are in relation, so if increase pressure of the air and still want to have control of the results, we need to increase as well speed of machine. This kind of play with fabrication parameters gives us possibili-ties to stick layers on the top of each other. Rectangle example with diagonal and without diagonal opens us possibilities to think about geometry of the layer sec-tion. So if we want to build more in the height we need more ellipse section, but that brings less effective manufacturing process.Experiment with inclination limit with simple circle open us great new possibilities to print clay with angle up to 60 %. Still section of the wall object of the clay is im-portant, if we have more pressure we have more stronger wall what results more inclination.Definingthissecuritylevelofthesectionisfirstimputingfordigital simulation, what open great possibilities to optimize amount of material but still save form possibilities for demand form finding.Still in this phase we are led by our intuition, so experiment with overlapping points inside of each layer give us even bigger inclination and higher structure. We can say this was solved problem of two previous experiments where we have G-code with very simple geometry of get- ting higher and bigger inclination. This gives us huge polygon of playing not only with machine and material parameter, but also with specific characteristic of digital geometry input.FABRICATION{ CONTINUOS }Themaincharacteristicoftheprojectishowtotranslate2Dlayerto3Dshape, inotherwords,howtoharmonizemachinemovementandmaterialbehaviorin ordertobuild3Dshapes.Sim-pleexperimentwithshapegetfromeightmove-ments, served us to conclude that if we overlap layer in the same level we can get morestructuraleffectofthebuildshape.Certainly,behindpatternsofthema-chinemovement,eightshapeshelpustounderstoodmaterialbehaviorinpar-ticularscale,forexampledryingtime,propertiesofthemixtureetc.Allofthese parameters are rules of the coding softer for generating families of the patterns.Epicycloidisaplanecurveproducedbytracingthepathofachosenpointofa circle - called an epicycle - which rolls without slipping around a fixed circle. It is a particular kind of roulette. Parametric mathematical equation of the epicycloid gives us possibilities to implement mate- rial rules in the digital model of machine movement. Number of the interpolated points of the layer and their relations such us distance from each other, or density in particular zone of the section are rules defined by material properties.Parameterwhatdefinedscaleoftheepicycloidisdryingtimewhatisinrelation with thickness of the layer. For example, if time of executing one layer is less than drying time of same layer we need to change path to avoid collision and bad bind-ing of two layers. Creating families of the one particular pattern of the epicycloid open as well possibilities to make different kind ofPROCESS OF A EPICYCLOID1 2 3 4 5 6 -2 -3 -4 -5 -6 -11-1-2-4-5-6-3236541 2 3 4 5 6 -2 -3 -4 -5 -6 -11-1-2-4-5-6-3236541 2 3 4 5 6 -2 -3 -4 -5 -6 -11-1-2-4-5-6-3236541 2 3 4 5 6 -2 -3 -4 -5 -6 -11-1-2-4-5-6-323654(R+r)sin(R+r)cosr cos(+)r sin(+)LR= LrXYFORMULA OF EPICYCLOID1 step2 step3 step4 stepR*((1-k)*cos(t)+l*k*cos(((1-k)/k)*t))R*((1-k)*sin(t)-l*k*sin(((1-k)/k)*t))CONTINUOUSFABRICATION{EPICYCLOID}104 105{FabClay} FABRICATION {FabClay} FABRICATIONEPICYCLOIDkRl = 0.85= 64= -1kRl kRl = 0.08= 59= -7{kRl = 0.45= 56= -5{EkRl = 0.53= -30= -2{EkRl = 0.059= 67= -3{E= 0.85= 64= -1{E EkRl = -1.21= -46= -4.2{EkRl = 0.56= 25= -5{EkRl = 0.34= 130= -1{EkRl = -0.42= -61= 2{E= 0.727273= -185= 5{EkRl = -67= -98= 0.4{EkRl = - 3.4= -7= -1{EkRl = 0.727273= 11= 0.4{EkRl kRl = 0.43= -30= -4{E{EkRl = 0.04= -13= -2{EkRl = 0.082= -25= -2{EkRl = 0.67= -56= -12{EkRl kRl = 0.72= 11= 0.4{E= 0.2= -25= 0.4{E106 107{FabClay} FABRICATION {FabClay} FABRICATIONEPICYCLOIDSPIROGRAPH David LittleMathematics DepartmentPenn State Universityhttp://www.math.psu.edu/dlittle/java/parametricequations/spirograph/index.html1 2 3 4 5 6 -2 -3 -4 -5 -6 -11-1-2-4-5-6-323654789121110-7-8-10-11-12-97 8 9 10 11 12 -8 -9 -10 -11 -12 -7 1 2 3 4 5 6 -2 -3 -4 -5 -6 -11-1-2-4-5-6-323654789121110-7-8-10-11-12-97 8 9 10 11 12 -8 -9 -10 -11 -12 -7108 109{FabClay} FABRICATION {FabClay} FABRICATIONIn order to get smart independent material-machine process, translation rules of thematerialandmachineexperimentsinthedigitalenvironmentsisimportant step. Scripting as tool for this process opens great possibilities to implement all this parameter in one whole and then simulate all experiments for which we dont have time, or even check they relevance for the pro- ject. This simulation consist parametricgeneratorofthepattern,rulesfortheinclination,differ-enttypeof material and simulation movement of many nozzle. These rules are represented insecuritieslevelswhicharecheckinglimitsofbuildabilityofthemodel.Inthe simulation we are able to change material what represent different pressure of the air or different viscosity of the mixture. With digital simulation we are trying to find relationbetweenpatternandinclinationlimits,indeedlengthoflayerandangle limit degree and still saving possibilities to check mate- rial properties influence.FROM 2D TO 3DDIGITAL SIMULAITIONMACHINE CONTROLOPTIMIZATION{PROCESS}MACHINE EXPERIMENREAL EXPERIMENTSMODELADJUSTMENTNEW EXPERMIMENTDIFFERENT SCENARIOSDESING110 111{FabClay} FABRICATION {FabClay} FABRICATIONCOMPUTATIONAL{OPTIMIZATION}kR = 1= 25 {EkR = 1= 25kR = 2.1= 25 {EkR = 7.2= 25 {EkR = 5.5= 25 {EkR = 4= 25 {E{ANGLE75{ANGLE60{ANGLE45{ANGLE30{ANGLE101 STEP - ANALYSIS OF EXAMPLES WITH ANGLES SELF-INTERSECTIONS{DIGITAL SIMULATION}112 113{FabClay} FABRICATION {FabClay} FABRICATIONSIMULATION OF EPICYCLOID IN THE PROCESSING{DIGITAL SIMULATION / INTERFACE}SIMULATION OF EPICYCLOID IN THE PROCESSING STEP BY STEPStart Bulding SimulationStop To Bulding SimulationEpicicloideRadiusInclinationMaterialSimulationNozzleMaterial FallingSimulation114 115{FabClay} FABRICATION {FabClay} FABRICATION2 STEP - ANALYSIS OF EXAMPLES WITH ANGLES SELF-INTERSECTIONS{DIGITAL SIMULATION}INCLINATION69 %K = 11.3MULTICRITERIA OPTIMIZATION 54%80%100%33200 cm30%REVELANCEMANIFACTURINGBUILDING INFORMATIONAMOUNT OF MATERIALMATERIALMATERIALMANIFACTURINGINCLINATION50 %K = K12MULTICRITERIAOPTIMIZATION 71%71%100%1435 cm341%REVELANCEMANIFACTURINGBUILDING INFORMATIONAMOUNT OF MATERIALMATERIALMATERIALMANIFACTURINGINCLINATION58 %K = 28MULTICRITERIA OPTIMIZATION 54%89%89%13955cm30%REVELANCEMANIFACTURINGBUILDING INFORMATIONAMOUNT OF MATERIALMATERIALMATERIALMANIFACTURINGINCLINATION65 %K = 8.5MULTICRITERIAOPTIMIZATION 3.4%34%34%5408cm30%REVELANCEMANIFACTURINGBUILDING INFORMATIONAMOUNT OF MATERIALMATERIALMATERIALMANIFACTURING116 117{FabClay} FABRICATION {FabClay} FABRICATIONINCLINATION45 %K = K10MULTICRITERIAOPTIMIZATION 71%51%51%1109 cm378%REVELANCEMANIFACTURINGBUILDING INFORMATIONAMOUNT OF MATERIALMATERIALMATERIALMANIFACTURING2 STEP - MULTICRITERIA OPTIMIZATION OF MACHINE OF MATERIALPROCESS THROUGH INCLINATION AND PATTERNS {DIGITAL SIMULATION}INCLINATION45 %K = 6.3MULTICRITERIA OPTIMIZATION 15.4%100%100%4604 cm37.4%REVELANCEMANIFACTURINGBUILDING INFORMATIONAMOUNT OF MATERIALMATERIALMATERIALMANIFACTURINGINCLINATION25 %K = 10MULTICRITERIA OPTIMIZATION 35%100%100%3505cm329.7%REVELANCEMANIFACTURINGBUILDING INFORMATIONAMOUNT OF MATERIALMATERIALMATERIALMANIFACTURINGINCLINATION25 %K = 2MULTICRITERIAOPTIMIZATION 91%90%90%326cm392%REVELANCEMANIFACTURINGBUILDING INFORMATIONAMOUNT OF MATERIALMATERIALMATERIALMANIFACTURING118 119{FabClay} FABRICATION {FabClay} FABRICATION120 121{FabClay} FABRICATION {FabClay} FABRICATIONCONCLUSION OF THE OPTIMAZATION First level of optimization process is check-ing how much our digital model is far away from the real experiments. This process iscalledmodeladjustmentprocess,wheregenericalgorithmusingrandomval-ues to correct result of digital simulation. Second level of optimization process is usingresultsfrommodeladjustment,indeeduserulesofphysicalexperiments todigitallycheckrandompatternandrandominclinationlimits.Againusingge-netic algorithm allows calculating build possibilities of the experiment, amount of ma- terial and multicriteria optimization. All of this parameter are in relation with pattern,soifweareusingmoreinterpolatedpointsinside2dlayerandbuilding small angle, we know that this is successful 100 percent. But if we know that we are using too much material for not demanding angle we are considering that this experiment is not optimized trough material but is trough manufacturing criteria. Therefore we can sort particular equation of movement of machine for the particu-lar project what confirming relation of the interpolated points with freeform level.Fabrication of the column is process based on the small experiments and digital simulationmodel.FirstexperimentisdoneontheCNCmachinewithlimitedz-axis height what allows only check how many point we can overlap and avoid colli-sion of the overlapped layers. Also we still have ideas how to change parameters of epicycloid, but only in digital model, because of CNC scale limit. Biggest challenge after switching to KUKA robot is how to translate all our results and rules in the big-ger scale. Parameter such as drying time or number and distance from each inter-polated points inside patterns are changed in this new process. Therefore, we are bring- ing new decision in terms of fabrication such as holes inside or limit of the freeform in order to reduce amount of the material and machine time executing. In this moment all fabrication are indeed design parameters which are defending eventually architectural proposal.Last fabrication experiment is investigating eventually possibilities to print double wall, where we will able to burn our model. This process is not only demand trough success of fairing, but also to fabricate. Pattern of the oven doesnt have any more too much support from inside walls, now all structural forces are orientated to the surface walls, what resulting lover freeform122 123{FabClay} FABRICATION {FabClay} FABRICATIONFABRICATION{COLUMN}COMPUTATIONALAND PHYSICAL PARAMETER TO FABRICATEA COLUMN {FABRICATION AT REAL SCALE}SECCIONS CONNECTIONS PATH TO G-CODE1 PATHEpicycloid3 PATHEpicycloid4 PATHEpicycloidPATH FROMTHE G-CODEmaterial viscositymax2 mm4 brMATERIAL BEHAVIOR DESCRIPTIONSCOMPUTATIONALG-CODE FROMGRASHOPPERAND KUKA-PRCFABRICATIONLENGTH OF PATH 83.463 mtsTIME FABRICATED 26 HOURSMACHINE KUKANOZZLES 303D MODEL124 125{FabClay} FABRICATION {FabClay} FABRICATION126 127{FabClay} FABRICATION {FabClay} FABRICATIONCOMPUTATIONALAND PHYSICAL PARAMETER TO FABRICATEA COLUMN {FABRICATION AT REAL SCALE}SECCIONS CONNECTIONS PATH TO G-CODEmaterial viscositymax2 mm4 brMATERIAL BEHAVIOR DESCRIPTIONSCOMPUTATIONALG-CODE FROMGRASHOPPERAND KUKA-PRCFABRICATIONLENGTH OF PATH 15.463mtsTIME FABRICATED 2 HOURSMACHINE KUKANOZZLES 41 PATHEpicycloidPATH FROMTHE G-CODE3D MODELMODELFABRICATED128 129{FabClay} FABRICATION {FabClay} FABRICATIONPERFORMACE MACHINE 0%PERFORMACE MACHINE 1%PERFORMACE MACHINE 20%PERFORMACE MACHINE 40%PERFORMACE MACHINE 60%PERFORMACE MACHINE 99%130 131{FabClay} FABRICATION {FabClay} FABRICATIONCOMPUTATIONALAND PHYSICAL PARAMETER TO FABRICATE{FABRICATION AT REAL SCALE}SECCIONS CONNECTIONS PATH TO G-CODEmaterial viscositymax2 mm4 brMATERIAL BEHAVIOR DESCRIPTIONSCOMPUTATIONALG-CODE FROMGRASHOPPERAND KUKA-PRCFABRICATIONLENGTH OF PATH 63.463mtsTIME FABRICATED 18 HOURSMACHINE KUKANOZZLES 181 PATHEpicycloid2 PATHEpicycloid3 PATHEpicycloid4 PATHEpicycloid5 PATHEpicycloidSECCIONS INTHE G-CODEPATH FROMTHE G-CODE3D MODEL132 133{FabClay} FABRICATION {FabClay} FABRICATION134 135{FabClay} FABRICATION {FabClay} FABRICATIONCOMPUTATIONALAND PHYSICAL PARAMETER TO FABRICATEA OVEN {FABRICATION AT REAL SCALE}SECCIONS CONNECTIONS PATH TO G-CODEmaterial viscositymax2 mm4 brMATERIAL BEHAVIOR DESCRIPTIONSCOMPUTATIONALG-CODE FROMGRASHOPPERAND KUKA-PRCFABRICATIONLENGTH OF PATH 278.5 mtsTIME FABRICATED 13 HOURSMACHINE KUKANOZZLES 173D MODEL2 PATHEpicycloid1 PATHEpicycloid4 PATHEpicycloid5 PATHEpicycloid3 PATHEpicycloidPATH FROMTHE G-CODE136 137{FabClay} FABRICATION {FabClay} FABRICATION138 139{FabClay} FABRICATION {FabClay} FABRICATIONAPPLICATION{ ARCHITECTURE }If we can generate technologies as tool to add material rather then subtract, we cancontrolmaterialcomposition,withthatopportunitiescancomputevarious functioninsidematerial.Processofgroovingformtroughlayeringopensgreat possibilities to make different relation or properties of the each small layer, what resulting as many different possibilities. In other words, we can define amount of material and with new technologies let design emerge by itself.Clay in this digitally control of material process showed as one very powerful ma-terial, all of disadvantages such as draying time or shrinking can be corrected in digital simulation and then depend of design scenarios be implemented in fabrica-tion process. This new digital fab- rication technique brings a lot of advantages in terms of economy, fabrication process, self- sustainability and design. From econ-omy point of view printing clay in scale of house, offering less people involved in all project, low cost transport and material resources. Fabrication and design pro-cess are more interpolated ant time from making design decision and executing is shorter. What opens as well more involved user in all process and better solution for them. With this technologies revolution we are much more able to be involved in rethinking of today urban landscape and brining new way of consuming our en-vironment.APPLICATION{architectural}142 143{FabClay} APPLICATION {FabClay} APPLICATION144 145{FabClay} APPLICATION {FabClay} APPLICATION146 147{FabClay} APPLICATION {FabClay} APPLICATION148 149{FabClay} APPLICATION {FabClay} APPLICATIONDevelopersStarsk Lara Nasim Fashami Sasa JokicProfesorMarta Male-Alemany AssitentsJordi Portell Miquel Lloveras Santiago MartinIaaCBarcelona - Spain2011 - 2012All rights reserved2012Fab(){ Clay ;} Starsk LaraSasa JokicNasim Fashmi{ digital tectonics }2011/2012