8/10/2019 PlasticityBoards_Round2
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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
8/10/2019 PlasticityBoards_Round2
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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.
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