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 SEAMING & PUFFING DIGITAL PUFFING SEAM FIGURATION PUFF’D PUFF’D prototype explores plasticity of COMPOSITE construction and the role of the seam and joint in architecture. Inspired by Japanese wood joinery, puffy jackets and jet fighter airplanes, PUFF’D pro- poses a novel construction technique for full scale architecture. Instead of following parametric paneling and module-based logics, PUFF’D employs large monolithic building components or SUPER-COM- PONENTS suggesting new ways of full scale assembly on site. The project follows up on our previous explorations including studies of super-componen ts, joinery, material agency, and robotic assembly. The previous prototype used the language of stitching and wood joinery to study how composite tectonics would utilize a MEGA-SEAM for a simplified assembly and explored the role of real and fake seams in architectural assemblages. The current proposal scales up and develops an inflatable composite sandwich technique to minimize waste and explore new formal and structural possibilities. PUFF’D alters the aesthetic of traditionally seen and recognized materiality and displays a structural system that appears soft in nature. Unlike current facades or shell systems the injected surface presents itself as a soft surface not recognized yet in architectural applications. A precise tectonic seam and stitching pattern encoura ge an inexact articulated soft surface treatment. The form of the prototype is a folded envelope with hyperbolic surfaces. COMPOSITES / SUPER COMPONENTS / METASEAMS BRENNEN HULLER / NELS LONG / NIKITA TROUFANOV

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PROTOTYYPE GEOMETRY 

TOPOLOGICAL PUFFING

PUFF EVOLUTION

SEAMING & PUFFING

STRUCTURAL ANALYSIS & REINFORCEMENT THROUGH PUFFING

GRADIENT/HALFTONE PUFFING FIGURAL PUFFING

TEX-FAB FULL PROTOTYPE FABRICATION & INSTALLATION STRATEGY 

DIGITAL PUFFING

ROBOTIC STITCHING: DOUBLE ROBOT NEEDLE & HOOK SEWING

ROBOT_1 W/

NEEDLE & FOOT

END EFFECTOR

ROBOT_2 W/

SHUTTLE HOOK 

END EFFECTOR

DOUBLE LAYER

FIBERGLASS

FIXED TO FRAME

ROBOT_1 W/

UNIVERSAL SPRAY 

END EFFECTOR

ROBOT_2 W/

UNIVERSAL SPRAY 

END EFFECTOR

3D PRINTED KEYS TYP. (9X)

(Z-LOCKING)

FINISHED COMPONENTS TYP. (5X)

(W/ X-Y LOCKING JOINTS)

COMPONENTS SNAPPED

INTO PLACE BY 2 PEOPLE

KEYS LOCKED

BY 1 PERSON

1

3/1-A 

4/3-B

4/3-A 

5/4-B

5/4-A 

4/2-A 

5/2-B

5/2-C

5/2-A 

2 3

45

2 KINECT

3D SCANNERS

FOR EVAL’N

PUFFED COMPONENTS

FIXED TO FRAME &

JOINT RAILS

EXPLODED COMPONENTS DIAGRAM ASSEMBLY ON SITE WITH 3 PEOPLE

FOAM INJECTIONS UNROLLED STITCHING PATTERNS

ROBOTIC FOAM PUFFING, RESIN SPRAYING & FINISHING

SEAM FIGURATION

STRESS FALLOFF LINES PRINCIPLE STRESS GRADATION STRUCTURAL INFLATION

PUFF’D

PUFF’D prototype explores plasticity of COMPOSITE construction and the role of the seam and joint in architecture. Inspired by Japanese wood joinery, puffy jackets and jet fighter airplanes, PUFF’D pro-

poses a novel construction technique for full scale architecture. Instead of following parametric paneling and module-based logics, PUFF’D employs large monolithic building components or SUPER-COM-

PONENTS suggesting new ways of full scale assembly on site. The project follows up on our previous explorations including studies of super-components, joinery, material agency, and robotic assembly.

The previous prototype used the language of stitching and wood joinery to study how composite tectonics would utilize a MEGA-SEAM for a simplified assembly and explored the role of real and fake

seams in architectural assemblages. The current proposal scales up and develops an inflatable composite sandwich technique to minimize waste and explore new formal and structural possibilities. PUFF’D

alters the aesthetic of traditionally seen and recognized materiality and displays a structural system that appears soft in nature. Unlike current facades or shell systems the injected surface presents itself

as a soft surface not recognized yet in architectural applications. A precise tectonic seam and stitching pattern encourage an inexact articulated soft surface treatment. The form of the prototype is a

folded envelope with hyperbolic surfaces.

COMPOSITES / SUPER COMPONENTS / METASEAMSBRENNEN HULLER / NELS LONG / NIKITA TROUFANOV

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3

TOOL

KEY 

LOCK 

LAP JOINT

W/ TEETH

CONSTRUCTION SCALE SEQUENCING PROPOSAL

JOINT AT KEY 

1 2

JOINT AT TYP. LAP

JOINT CONDITIONS DETAIL JOINT TECTONIC

PARTIAL PROTOTYPE FABRICATION WORKFLOW

PARTIAL PROTOTYPE CLOSE-UPS

PUFF’D COMPOSITES / SUPER COMPONENTS / METASEAMSBRENNEN HULLER / NELS LONG / NIKITA TROUFANOV

The built prototype displays the injected sandwich COMPOSITE technique with stitching patterns derived from the structural analysis of the form. Building PUFF’D is broken into the assembly of rigid joints

and flexible fabric components. The joint is constructed out of carbon fiber to achieve a base rigidity to the SUPER-COMPONENT. The stitching of the fiberglass fabric was executed with stretchable

thread allowing the injection of spray foam to inflate t he panel system. Once completed the joint is embedded within the fabric and fastened in place via resin then injected with foam in specific volumes to

area based on previous analysis. Once the panel has expanded multiple coats of resin creates a composite MONOCOQUE panel allowing a singular tectonic to connect finished panels to one another creating

a simplified on site construction process. The panels are designed with teeth to assist in assembly and minimize sheer loads but are fully fastened with a 3d printed key mechanism and specialized tool. At

the pavilion scale these components can be assembled with as few as three people in under twenty minutes using only the printed hardware and tool. At a larger scale the fabrication process allows the

fabric to be rolled on site and attached to the rigid rails prior to applying resin. This allows for enhanced shipping and assembly of architectural components and encourages the use of robotics to assist

with the on site applications of injecting and resin application.

PATTERNS

UNROLLED

PATTERNS

ROLLED-UP

PATTERNS

PUFFED & CURED

TRUCK W/

SPRAY FOAM

COMPONENETS

LIFTED INTO PLACE

BOOM-ARM

CRANE TRUCK 

KEY IN LOCKED

POSITION (ABS)

INSULATION

SPRAYFOAM

17 OZ STICH MAT

FIBER GLASS

9 OZ CARBON FIBER

AT JOINT

STITCH

TYP.