3d Printing developments | Star Lounge & other developments by Emerging Objects & Bold Machines

Emerging Objects

2015

The use of 3d printing in architecture is one of the research fields of these years. Printing time, printing size and the capacity of being structural are some of the main issues that we are still dealing with nowadays. Emerging Objects, together with the help of Bold Machines, was able to develop a free standing 3d structure, taking advantage of the geometry used. The geodesic dome is made of 2073 hexagonal translucent blocks and their colour differs so to facilitate the assembly.  

It is interesting to see how the concept of 'production' changes with 3d printing, as opposed to more traditional construction materials. In order to create the pieces of Star Lounge, a real factory of 100 3d printing machines was used. Here, each machine was able to print an average of two pieces in just more than one hour. One great advantage is that the connections and the numbering were included in the printing of the pieces, leaving the part of the assembly just to screwing the pieces together.

Here there is a video of the assembly process, done by parts. https://vimeo.com/129315252

The work of Emerging Objects does not limit itself to the construction of small lounges, rather their aim is to apply this technique to the construction of houses and possibly bigger buildings. 

One step closer to achieve this goal was made a couple of years ago, when the team was able to patent a cement polymer for 3d printing, a material that can be reinforced with fiber, becoming even stronger and lighter than standard concrete. 

Source: http://www.emergingobjects.com/

Timber Panels | Landesgartenschau Exhibition Hall by ICD/ITKE/IIGS University of Stuttgart

University of Stuttgart, Germany

2014

The Landesgartenschau Exhibition Hall is a remarkable example of the use of plywood plates as structural material. The small pavilion is built with 243 50mm thick beech plywood plates, designed with the aid of computational technology. The use of a dome-like shape, together with computer simulations helped the team to reduce the amount of material to just 12m3 of plywood! 

Sources: http://www.archdaily.com/520897/landesgartenschau-exhibition-hall-icd-itke-iigs-university-of-stuttgart/

Cellophane House| Kieran Timberlake Architects

The Cellophane House by Kieran Timberlake Architects is a great example of design for assembly and disassembly. The project was realized as a result of a competition together with the MoMA, where the full scale prototype was built. The use of aluminium frame makes the building lightweight, minimizing the embodied energy, but also it allows the pieces to be disassebled and reused, even before coming to the recycling phase. Partitions and floors are made of structural translucent plastic. 

Here there is a nice time lapse of the building process lasted 6 days:

https://vimeo.com/76278529

Source: http://www.kierantimberlake.com/pages/view/14/cellophane-house/parent:3,
http://www.architonic.com/it/pmsht/clear-pep-uv-pc-stage-design-composite_proai/1080204,
http://www.boschrexroth.com/en/us/products/product-groups/assembly-technology/manual-production-systems/lean-podcasts/index,
http://www13.boschrexroth-us.com/Catalogs/R980-500-380_Architecture_Brochure_0809.pdf

Plastic Bricks | Isinnova

The example of the Brick is still a study for now, due to the lack of funding. However, I think the idea of this Italian engineer could be very interesting. Brick is a system of plastic bricks (basically like Lego pieces) which would allow a group of three people to build a 120m2 house in one day. The pieces would be sold separately and the customers could design their own house. The company would later check the habitability of the house.

Source: http://corriereinnovazione.corriere.it/coverstory/2015/6-marzo-2015/costruire-casa-mattoni-plastica-invenzione-rivoluzionaria-brescia-2301073030397.shtml
http://milanopost.tumblr.com/page/2

Brick Panels | Schiecentrale 4B by MEI Architecten

 

Schiecentrale 4B by MEI Architecten
Rotterdam, Netherlands;

The example of the Schiecentrale 4B in Rotterdam is an interesting example of the addition of prefabricated components to an existing building block. The project consists on the renovation of a former power plant in order to provide housing and working space. The external additions that are visible just on one of the façades are storage units for the apartments.

Sources:DETAIL, Issue 06/12, pp.880-883

Brick Panels | Psychiatric Center by Huggenbergerfries Architekten

Psychiatric Center by Huggenbergerfries Architekten
Pfafers, Switzerland;

The example of the Psychiatric Center in Pfafers is an interesting example of the combination of typically wet construction systems (brick façade) with prefabrication, which guarantees more precision and better working conditions. It is not so much about industralization, especially in the production process since the bricks were placed manually one after the other. Despite this, great optimization was thought in order to obtain panels with different textures.

Sources:DETAIL, Issue 06/12, pp.568-571

Aluminum Rainscreen Panels | Wyly Theater by REX Architects/OMA

Dee and Charles Wyly Theater by REX/OMA (façade designed by Front)
Dallas, Texas; 2009
While the Wyly Theater is probably best known for its programatic innovation, its skin contributes to make the building unique. The skin acts as a rainscreen and it is made of six different aluminum extrusions, arranged in six different combination. This allows the panels to vary along the façade and give at the same time a sense of vibrancy to the building. The aluminum elements are fixed to some horizontal metal fixings and the ones with the biggest sections also include exterior illumination for the building itself as well as for the signage.

Sources:
http://archrecord.construction.com/projects/portfolio/archives/1002wyly_sb/2.gif
http://www.rex-ny.com/work/wyly-theatre/construction
http://www.archdaily.com/12521/wyly-theatre/

Modular Hotel Rooms | Hotel Ammerwald by Kaufmann & Rüf

BMW Hotel Ammerwald by Kaufmann & Rüf
Dornbirn, Austria; 2012

Hotel Ammerwald in Austria is an interesting example of the use of modularity in the construction of such an extensive building. The use of modular rooms was decided both because it would guarantee factory quality standards but also because of the difficult weather conditions on site.
With their horizontal lines, the first two floors are made of cast in situ concrete, in order to give a solid base, especially knowing that, in winter, snow can cover part of these floors. On top of this base, there are three more floors composed of prefabricated timber rooms, finally covered in situ by a sheet of steel. The 96 modular rooms were produced in 31 days by a factory less than 100km away. Later they were transported by trucks and placed in their position in only 10 days.

Here there is a video explaining the construction process (it is in German but still quite explanatory):
http://www.detail.de/architektur/themen/hotel-bei-reutte-018877.html


Sources:
DETAIL, Issue 06/12, pp.553-557
Competitionline. Accessed February 7, 2015.
http://www.competitionline.com/de/projekte/44838

Precast Concrete Façade | Perot Museum of Nature & Science by Morphosis

Perot Museum of Nature & Science by Morphosis
Dallas, Texas; 2008-2013

The example of the new Perot Museum of Nature & Science is particularly interesting in terms of latest technologies because this project is characterized by an extensive use of computer aided modelling (BIM) which did not only help the architect during the design phases but also the whole coordination that was needed in later structural calculations and construction. The use of this technology is especially noticeable in the pre-cast concrete façade, which is designed to resemble geological formation. The skin is made of 700 elements with the same overall size but with a varying texture. In order for the façade to be developed with a continuous texture between the modules, a mold system of 39 geometry families (both recessed and protruding) was studied, creating a series of 4 panel shapes in 12 patterns. The 39 mold pieces were each time assembled in different combinations, in order to cast a new panel. This systematic and computerized technique guaranteed a customized façade, delivered on time and within the budget. The concrete panels are load-bearing and fixed to the metal structure of the building.

Here there is a time-lapse of the overall construction:
https://www.youtube.com/watch?v=yfMYqxWe9X0

Sources: AIA. "Perot Museum of Nature and Science. AIA TAP AWARDS 2014". Accessed January 21, 2015. https://higherlogicdownload.s3.amazonaws.com/AIA/Citation%20-%20Perot%20Museum%20of%20Nature%20and%20Science5.pdf?AWSAccessKeyId=AKIAJH5D4I4FWRALBOUA&Expires=1421878949&Signature=SU3KlIZPbmuUxg2Qr3SUKC4fR4s%3D.
Collaborative Design Workflows. Accessed January 21, 2015. https://doarchworkflows2014.files.wordpress.com/2014/12/arch-421-research-project-27.jpg
SYNOSIS. Accessed January 21, 2015. https://synosis.wordpress.com/.