Posts tagged with "digital design":

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KVA Brings Digital Brick to Harvard

Old and new technologies combine in renovated anthropology building.

Tasked with transforming Harvard's 1971 Tozzer Library into a new home for the university's Anthropology Department, Kennedy & Violich Architecture (KVA) faced a unique set of challenges. In addition to balancing the desire for a distinct architectural identity with the building's literal and metaphorical connection to adjacent structures including Peabody Museum, the architects had to accommodate an expanded program within the old library's footprint and structure. As for Tozzer Library's facade, a mold problem and poor environmental performance meant that preserving the brick exterior was never an option. "It's a generic problem of envelopes from buildings that aren't that old, yet can't stand up to contemporary needs," said principal Sheila Kennedy. "What are you going to do with those buildings? The bold approach here was, 'we're going to build on [the existing] value." By stripping Tozzer Library down to its steel and concrete-slab bones, adding space under a two-story copper roof, and wrapping the exterior in a parametrically-designed brick skin, KVA seamlessly negotiated between Harvard's storied past and the mandates of a 21st-century curriculum. Both Kennedy and founding principal J. Frano Violich are quick to dismiss the notion that the problems with the 1971 building, designed by Boston firm Johnson, Hotvedt and Associates, were anything other than a product of their times. "Attitudes toward energy consumption were very different at the time," said Violich. "[Tozzer Library] was built by intelligent people, but everyone's understanding was different from today." In contrast, he said, for the new Tozzer Anthropology Building, "everyone was on top of every [LEED] point." (The project achieved LEED Gold.) KVA began by substituting 6-inch wall studs for the original 2 1/2-inch studs, making way for improved air circulation and insulation. In addition, they eliminated the potential for mold growth by increasing the air gap between the outside sheeting and the back of the brick veneer from 3/4 inches to 2 inches. With the mechanics of the exterior walls in place, "the challenge, aesthetically, was how do we get a sense of both thickness and thinness in the veneer?" said Violich. Luckily, the question of how to breathe new life into flat surfaces was nothing new for the architects. "At KVA we've been very interested in how one designs with contemporary wall systems, with materials that are thin," explained Kennedy. "How do we express their thinness, but by architectural means and devices give them an architectural thickness, manipulate them formally so there can be a game of thin and thick?" In the case of Tozzer Anthropology Building, the answer was a new entrance pavilion with a three-dimensional brick pattern meant to "seem like carved thick brick—like an archeological find," said Kennedy. Drawing upon their early experiments with digital brick, including those at the University of Pennsylvania Law School building, the designers used parametric design software to tie each brick unit to the building's overall form. "As we manipulated the physical form in 3D, we could see various brick patterns that could develop," explained Kennedy. "It was a hybrid of low-tech and high-tech," she said of the process of zeroing in on corbeling, a brick-stacking technique that allows for overhanging layers. The digitally-derived corbeled texture complemented the depth of ornament found elsewhere around Harvard's campus. "We didn't want to make something that was arbitrary and ornamental, but something that was authentic to our time," said Kennedy. To arrive at a final design for the multi-story entrance wall, the architects again combined cutting-edge technology with traditional expertise. "The actual pattern was achieved through physical experimentation," explained Kennedy. "We did a lot of dry stack work with local masons: We would take the designs out of the computer, then pass them to the masons to test. That was a really fun part of the process." KVA then took what they learned from their real-life experiments back into the virtual world, adjusting the digital design accordingly.
  • Facade Manufacturer Kansas Brick (brick), Wasau (glazing)
  • Architects Kennedy & Violich Architecture
  • Facade Installer Consigli (masonry), Gilbert & Becker Roofing (copper)
  • Facade Consultants BuroHappold Engineering
  • Location Cambridge, MA
  • Date of Completion 2014
  • System brick walls, including parametrically-designed corbeled entry pavilion, with high performance glazing and custom copper roof
  • Products 500 Harvard brick from Kansas Brick, Wausau 4250-Z Zero Sightline insert windows, Wasau 6250 S-Series SuperWall curtain wall system
Even the flat facades appear unlike typical brick walls, thanks largely to an unusual window arrangement. "When you're looking at the windows, you're not looking at traditional punch windows, or a strip window with a long relieving angle," said Violich. Rather, the windows are shifted to conceal the vertical control joints in the brick. "That helps defuse the veneer quality that brick sometimes brings on," he explained. The floor-to-floor windows further confound expectations by concealing the plenum and—because they are frameless, and punch out rather than in—appearing as much like light monitors as the actual skylights cut into the building's roofline. Tozzer Anthropology Building's recycled-content copper roof completes the dialogue between thick and thin established on the brick facades. "We worked hard in the massing of the design to give a twist to the building," said Kennedy. "That could really only happen in the two new floors." KVA textured the copper roof with vertical standing seams, again using parametric software to arrange different panel types in a corduroy-like pattern. "A lot of times people think advanced facades are super technical, but we can get lost in the technology and why we're using it," observed Kennedy. "[This project] is a good combination of an aesthetic agenda, an architectural agenda, and a technical agenda." For KVA, Tozzer Anthropology Building represents more than just a repurposed campus building. Rather, it offers a provocative answer to one of today's most pressing questions: how to rectify an inherited aesthetic preference for glass with the current push for improved energy efficiency. "Everybody loves glass—we love transparency in architecture," said Kennedy. "But as we move on in our energy transition, we're going to have to develop new ideas about mass and opacity. How can we go back to a pre-modern time, but create something that is contemporary?"
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Höweler+Yoon combine cutting-edge tech and age-old craft to complete the Sean Collier Memorial at MIT

On April 18th, 2013, the Boston Marathon bombers went on a crime spree that included the killing of Officer Sean Collier who was shot in the line of duty on the MIT campus. In honor of the slain MIT patrol officer, the university commissioned Boston-based Höweler+Yoon Architecture to design the Sean Collier Memorial—a somber, grey stone structure that marks the site of the tragedy. The heaviness of the unreinforced, fully compressive masonry structure is meant to convey the concept of “Collier Strong,” or strength through unity. Thirty-two solid blocks of granite form a contemporary version of a five-way vault. "Our goal was to not post-tension the structure, to make it compressive and use solid blocks," Höweler + Yoon principle Meejin Yoon told AN, "It could have been built out of concrete or steel, but we wanted solid blocks." The large stone pieces were digitally designed and fabricated to work as a self-supporting structural system. Forces are translated into form via a robust combination of cutting-edge computational processes and ancient techniques for making masonry structural spans. The stones were precisely milled within a .5 millimeter tolerance, so that they fit together perfectly to form a compression ring with a keystone that caps the shallow masonry arches. In the center of the buttressed vaults is a covered space for reflection. The buttresses act as walls that extend out to the surrounding campus context. The novel concept required many moving parts to work in harmony. "It is very pure. It is a simple idea," Yoon said. "It took so much collaboration to make this simple idea have the integrity that it did. There were students from 8 degree programs, including a PhD student, undergraduate architecture, undergrads in building technology, and grads in engineering and architecture." Engineering and design were intricately linked form beginning to end. The whole design process was influenced by a feedback loop of physical, analog, and digital models as well as digital simulation. Massive quarried blocks of stone were cut with a single-axis robotic block saw, then with a multiple axis KUKA 500 robot. Robotic milling processes made the tiny tolerances possible. Some of the blocks took as long as seven days to carve, with machines running 24 hours. Often, the cutting tools would wear down, causing the tolerances to change mid-fabrication. The team compensated by altering the digital model and then the next piece would change to match what had been previously carved IRL. Sensors were placed at each joint as the project was assembled on site. As stonemasons placed the high-tech monoliths into the 32-part final assembly, the structure was a choreographed symphony of new technology and timeless craft. The legible visualization of forces is parallel with the MIT ethos of openness and transparency, while the poetic nature of a dry masonry vault represents togetherness of the community in recovery. The project team also included structural engineer Knippers Helbig- Stuttgart, masonry consultant Ochsendorf DeJong and Block Consulting Engineers, landscape architect Richard Burck Associates, civil engineer Nitsch Engineering, geotechnical engineer McPhail Associates, lighting designer Horton Lees Brogden Lighting Design, and electrical engineer AHA Consulting Engineers.
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Learn and Earn CES LU Credits at Facades+ Los Angeles

In the fast-paced world of building design, hands-on instruction in new methods can be hard to come by. Next month, attendees at Facades+ LA can take advantage of a unique opportunity for one-on-one guidance in digital tools at tech workshops intimately connected to the themes of the conference. "The tech workshops are a great way to learn cutting edge methods that are regularly at the core of what is presented in the symposium and dialog sessions," remarked Thornton Tomasetti's Matt Naugle, a veteran Facades+ tech workshop instructor. On day two of the conference, Naugle will co-teach "Advanced Facade Panelization Optimization Techniques" with Thornton Tomasetti colleague Daniel Segraves. "This workshop is a unique opportunity to explore methods of optimization in Grasshopper with a pair of instructors who professionally use these methods on complex designs," said Naugle. "By the end of the day, all attendees will have a strong understanding of how to embed these methods into their own design and engineering methods." During the first half of the day, enrollees will learn how to apply algorithmic approaches to panelization optimization. The afternoon session will focus on dynamic optimization using Kangaroo. Naugle and Segraves will lead participants through examples that they either build themselves or pull from sample files, depending on their level of experience. "Throughout the day we will pause to discuss the reasons and logic behind the methods present—discussing the merit for each procedure on different use cases," explained Naugle. Other tech workshops featured at Facades+ LA include "Environmental Performance in Building Envelope Design," taught by Mostapha Roudsari, also of Thornton Tomasetti, and "Enhanced BIM Workflows for Data-Driven Facades," with Case Inc.'s Tim Dumatrait. All workshop participants will benefit from interaction with their peers as well as the instructors. "The workshop typically brings together a diverse collection of architects, engineers, facade consultants, manufacturers, and construction experts creating a great dialog about the methods being taught," said Naugle. Register online today—tech workshops fill up well before the conference weekend. For more information on Facades+ LA tech workshops, dialog workshops, and symposium events, visit the conference website.
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Dig Deep into Digital Design at Facades+ Dallas

Today’s AEC professionals are more to reach for a computer mouse then they are a drafting pencil. Understanding and being able fully utilize cutting-edge digital design tools is essential to contemporary architectural practice, particularly the design of high-performance building skins. Attendees at next month’s Facades+ Dallas conference can choose among four hands-on tech workshops in a unique program designed to deliver in-depth exposure to platforms including Autodesk Revit, Autodesk Vasari, and Grasshopper. The tech workshops, all of which focus specifically on building enclosures, “are heavily attended by professionals, by people wanting to take that next step and participate in a more active dialogue,” said Mode Lab’s Ronnie Parsons. “They are at once about learning, and about taking on the role of a leader who could potentially shape what’s happening—who could be on the podium next time.” The Dallas lineup includes “Computational Design for BIM,” taught by Parsons and Erick Katzenstein, also of Mode Lab; “Balancing Cost and Performance Through Simulation,” with HKS LINE’s Tim Logan and Paul Ferrer; “Parametric Facade Design Fundamentals,” led by Andrew Vrana of Metalab; and “Environmental Analysis and Facade Optimization Strategies,” taught by Colin McCrone and Mohammad Asl, both of Autodesk. Participants in “Computational Design for BIM” will also receive a one-month complimentary subscription to Mode Lab Academy. The tech workshops take place on the second day of Facades+ Dallas at CityPlace Events. They are designed to draw from and extend the discussions begun during the symposium on day 1, explained Parsons. “The way that the Facades+ conference has been crafted is in terms of a holistic experience.” For information and to register for tech workshops, visit the conference website.
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Martha Schwartz' Hillside Mountain Range

Illuminated steel pavilions mimic Chinese peaks.

The hillside site of Fengming Mountain Park, in Chongqing, China, presented Martha Schwartz Partners with both a practical challenge and a source of inspiration. Asked by Chinese developer Vanke to design a park adjacent to the sales office for a new housing development, the landscape architecture and urban planning firm quickly gravitated toward the metaphor of a mountain journey. "That's why in the plans you see a zig zag pattern" to the path leading down to the sales center from the car park, said associate Ignacio López Busón. Steel pavilions scattered along the walkway pick up on the theme, taking the form of abstracted mountain peaks. "That's something the client really liked," said López Busón. "Once the idea was clear, it was all about developing the shape of them, and trying to make them look special." To refine the image of the pavilions, explained López Busón, "we first looked at the faceted nature of Chinese mountains. They aren't smooth at all." Fengming Mountain Park's metal structures feature an aggressive geometry that twists and turns above chunky legs. The pavilions' perforations and red and orange color scheme were inspired by a second cultural touchstone. "Martha was interested in the idea of the Chinese lantern," said López Busón. "The lanterns are red; then you put a light inside, and they become a nice gradient of red and yellow." The Fengming Mountain Park team started work on the pavilions with hand sketches, then brought the concept design into Rhino. There they played with the shape, developing a system of triangular modules that again represented mountain peaks. Then they transferred the model to Grasshopper, where they focused on the perforations and color. "We made paper models, but not too many because we were quite happy with the result in Rhino," said López Busón, who acknowledged that a compressed schedule was also a factor.
  • Fabricator Third Chongqing Construction Engineering
  • Designers Martha Schwartz Partners
  • Location Chongqing, China
  • Date of Completion 2013
  • Material steel, spray paint
  • Process sketching, Rhino, Grasshopper, modeling, laser cutting, welding, spray painting
The most difficult aspect of fabrication, said López Busón, was adjusting the design of the pavilions to fit the size of the laser beds to which Third Chongqing Construction Engineering had access. "We made a Grasshopper definition to guarantee that every triangle fit the laser bed. However, the final outcome showed several scars, which tells us that the developer likely reused some leftovers to save on materials." Both the panels and the supporting profile tubes were fabricated out of steel, to reduce costs. Martha Schwartz Partners originally proposed painting individual panels after cutting, then assembling the finished panels on site. "The fabricators didn't agree," said López Busón. "They built the pavilions first, then spray painted them." The result, he said, was favorable. "What you see is a smooth gradient from the bottom to the top." The perforations, too, help negotiate the transition from ground to sky. "We came up with a pattern that changes from bottom to top, which sort of dissolves the pavilion," said López Busón. "It's quite nice at night. There's also this nice merging between decoration and structure; you can't tell what is what." The experience of designing a 16,000 square meter park on an abbreviated timeline "was intense, but fun," said López Busón. "At the very beginning, we were following this traditional way of practicing architecture: Whatever we designed in three dimensions, we unrolled and put into AutoCAD." But as the weeks flew by, the designers streamlined the process, sending 3D models directly to the client—a process, he explained, that allowed the designers to catch and immediately correct a problem with the perforation pattern. "Without the digital tools, it would have been impossible."
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Interactive Thermoplastic Pavilion by B+U

A thin shell pavilion with an audio feedback program invites engagement.

Apertures, the amorphous pavilion designed and fabricated by Baumgartner+Uriu (B+U) with students from SCI-Arc, challenges two of architecture’s defining dualities: the distinction between wall and window, and the division between exterior and interior. “Conceptually, we were looking at objects that are multi-directional and have apertures as their main theme,” said partner Herwig Baumgartner. “That was one aspect of it; the other was the barriers between inside and outside and how we can dissolve these. We’re interested in architecture that’s responsive through either movement or sound.” As visitors pass through or otherwise engage with the 16-foot-tall, 1/8-inch-thick structure’s many rounded openings, attached heat sensors trigger sounds based on human bio-rhythms, creating a feedback loop that encourages active exploration of the space. In addition to the themes of apertures and inside versus outside, B+U were interested in investigating the technology of thin shell structures. “How can you build something that’s over ten feet tall and very thin, and what’s the minimal material you can get away with?” asked Baumgartner. The architects used digital modeling software including Maya to determine the pavilion’s form, then constructed a series of mockups in different materials. “We’d be working with consultants, or we’d ask fabricators: how would they build this?” recalled partner Scott Uriu. “We were thrown quite a few interesting ideas. A lot of them wouldn’t quite pan out, but we were always working back and forth between digital and analog design.” The designers originally tried building Apertures out of acoustic foam. “It was interesting for us because it creates an absorptive environment, but it was very weak,” said Baumgartner. They considered supporting it with an egg-crate structure. “But in the end we said, ‘Let’s get rid of the structure and make the surface the structure,’” he explained. They landed on heat-formed plastic, a thin material that becomes self-supporting when molded into certain shapes. “We did a mockup and we really liked it,” said Baumgartner. “It’s glossy and shiny on the outside, but the inside was matte. It has a very different interior and exterior.” Matt Melnyck, a principal at Nous Engineering, worked closely with B+U to insure the pavilion’s stability.
  • Fabricator B+U with SCI-Arc students
  • Designers B+U
  • Location Los Angeles
  • Date of Completion 2014
  • Material thermoplastic polymer resin, aluminum rivets
  • Process Maya, modeling, CNC milling, heat forming, bolting, lifting
With 35 students from SCI-Arc, B+U CNC-milled polyurethane foam molds for the pavilion’s 233 panels. At Warner Bros. Staff Shop, they poured the hot plastic resin over the molds, then cut out and painted the components. Reveals and guides milled into the molds indicate attachment points; the panels are joined with aluminum rivets. On site at SCI-Arc, the design team assembled the panels into nine sections of 30-40 panels each before lifting them into place. Designed for easy assembly and disassembly, the structure “breaks down into 233 panels and nests well,” said Uriu. Media artist Hannes Köcher developed Apertures’ audio program based on B+U’s concept. “If you stick your head through the apertures or you walk through them, the majority of them have sensors. Different sensors trigger different sounds—we basically made a thermal map of the object,” said Baumgartner. “When you’re in the space and especially when there’s multiple people in the space, it heats up. The sound starts building up over time, almost like a polyphony thing.” Because the audio is delivered through transducer speakers, visitors feel as well as hear the rhythms. During its spring showing at SCI-Arc, the result was exactly as B+U had hoped, Baumgartner reflected. “People started interacting with it, entering into a sort of feedback with the sounds.”
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Hands-On Exposure to Cutting-Edge Technology at facades+Chicago

Contemporary architectural practice, and in particular the design of high-performance facades, is as much about mastering technology as it is about grappling with aesthetics and function. Attendees at next month’s facades+ Chicago conference will have an opportunity to explore cutting-edge digital design tools during a series of hands-on technology workshops. The tech workshops, which take place on the second day of the conference, follow a day-long symposium featuring keynotes and roundtable discussions by AEC industry leaders. “If on day 1 you’re being exposed to advancements in building methods, on day 2 you can learn the technology and techniques that are behind those applications,” said Mode Lab’s Ronnie Parsons. “It’s taking the next step from someone who’s in the audience to being a participant. Not just a participant who’s watching and engaged, but one who is actively involved in shaping what happens tomorrow.”Tech workshop topics include “Enhanced Parametric Design with Dynamo for Vasari,” “Advanced Facade Panelization and Optimization Techniques,” “Collaborative Design and Analysis with Grasshopper,” and Environmental Analysis and Facade Optimization Strategies.” “The technology being presented is at the edge of the industry,” said Parsons. “The people who are teaching them are at the edge. They’re writing the software and creating add-ons to the software.” At the same time, Parsons said, he and co-curator Gil Akos select workshop instructors on the basis of teaching ability as well as expertise. “We look for instructors who are leaders, but who also have the ability to engage, and to take participants on a ride for the day.” Parsons emphasized the close relationship between the conference symposium and the workshops. “Someone can come to the symposium and have a full and engaging experience, then continue that experience on day 2,” he said. “It’s not that these are separate, unrelated events. They are completely imbricated, completely reciprocal. It’s a holistic experience: there are two days with two different formats, but they’re meant to be one package.” For more information and to register for tech workshops, visit the facades+ Chicago website.
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James Timberlake to US AEC Industry: Bring Facade Manufacturing Home

KieranTimberlake has long pushed the boundaries of conventional facade design. The Philadelphia-based firm started using pressure-equalized rain screen systems in the 1980s, well before other architects brought the technology on board. Their Melvin J. and Claire Levine Hall, at the University of Pennsylvania (2003), was the first actively ventilated curtain wall in North America. The designers at KieranTimberlake have introduced new materials and assemblies, such as the SmartWrap building skin deployed at Cellophane House, part of MoMA’s Home Delivery: Fabricating the Modern Dwelling exhibit. One of the firm’s latest projects, the Embassy of the United States, London, incorporates an outer envelope of three-dimensional ETFE (ethylene tetrafluoroethylene) panels with integrated photovoltaic cells. Thus founding partner James Timberlake speaks from experience when he calls out the American AEC industry for a lack of attention to high-performance building envelopes. “We see performance—not only of the building, put particularly the facade—as being a critical element of architecture, and of the long-term sustainability of not only architecture but building in general,” said Timberlake. “We think that architects, manufacturers, and contractors need to be thinking innovatively in that way as they help build the future of not only North America, but China and Europe as well.” For Timberlake, who will deliver the keynote address at next month’s facades+ Chicago conference, the missing link is production. “I think the United States and North American market has abrogated its duty to produce high-performance, sustainable, and affordable facade choices over the last four decades,” he said. “The last time we produced anything that was innovative was in the late 1960s. Since then, all of that production went to Asia and Europe. I think it’s now time to make that stuff here.” Moving facade manufacturing back to the United States would benefit manufacturers and designers as well as the economy in general, says Timberlake. “The President of the United States has, in the last few weeks, put out a clarion call for manufacturing to return to the USA rather than offshoring. I think we can be competitive; I think we should be producing innovative wall strategies here,” he said, noting the potential impact on unemployment. “There have always been [American] companies that have been innovative with bespoke strategies, but at this point they are considered niche constructors. In the long term we would like to see those niche manufacturers expand their market reach to be the distributors for some of these other types of facade strategies, or even return to producing the kinds of curtain walls that made the Lever House and Mies van der Rohe’s buildings in Chicago, and made the gleaming skyscrapers of LA.” Architects, said Timberlake, would benefit from greater integration and lower labor and shipping costs were facade manufacture to relocate from abroad. The key to reintegrating facade manufacture and production, argued Timberlake, is demonstrating the existence of a market for cutting-edge envelopes. “They need to see that the design and engineering capability is here in the United States,” he said. “Three-dimensional design used to be the purview of Europe and Asia, but over the last five to ten years American architects and engineers have become quite capable of working three dimensionally. We’re turning out three dimensional designs and engineering solutions that are unique and innovative in terms of their technology, and also are affordable solutions and quite sustainable.” As proof that it can be done, Timberlake points to auto companies, including Volkswagen and Tesla, that have recently set up production centers in the United States. “I don’t see curtain walls and facades any different from that,” he said. “There’s a robust labor market ripe for that to be rolled out here.” Timberlake admitted that his concern with the building-products supply chain might strike some as unusual. “What architect thinks about that? We do,” he said, referencing KieranTimberlake’s history of integrating design and research. “We see economy as a part of design; design incorporates economy. You have to think about the market, sustainability, affordability, production, and manufacture. You have to think about how good it looks, and you have to think about whether you can get it to the marketplace.”

Digital Technologies and the Future of Facade Design

Among the AEC industry's most powerful tools are digital technologies, from parametric modeler software to environmental analysis programs. Neil Thelen (Diller Scofidio + Renfro), Gordon Gill (Adrian Smith + Gordon Gill Architecture), Edward Peck (Thornton Tomasetti), and Doris Sung (dO/Su Studio) took time out from April's facades+ NYC conference to talk to our partners at Enclos about how technology is shaping the future of envelope design. At next month's facades+ Chicago conference, a series of tech workshops will offer hands-on instruction in topics including facade panelization and optimization and collaborative design and analysis. For more information or to register, visit the conference website.
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Constructivist Playground by Warren Techentin Architecture

An interactive installation reconsiders the definitions of enclosure and openness.

Warren Techentin Architecture’s digitally-designed La Cage Aux Folles, on display at Materials & Applications in Los Angeles through August, was inspired by a decidedly analog precedent: the yurt. “Yurts are circular,” explained Techentin, who studied the building type as part of his thesis work at Harvard’s Graduate School of Design. “That began the idea of using small-diameter rods and taking software and configuring sweeps with some special scripts that we found online.” But while the yurt’s primary function is shelter, Techentin’s open-air installation, built of 6,409 linear feet of steel pipe, is a literal and intellectual playground, its form an investigation of the dualities of inside and out, enclosure and openness. Once the architects became familiar with the scripts, which allowed them to manipulate multiple pipes simultaneously, they found it easy to generate designs. The hard part was settling on a final shape. Then an off-hand observation narrowed their focus. “Somebody made a comment about, it looks like a crazy cage,” said Techentin. “We realized, ‘Oh, there’s this cage component. What if we imagine spaces inside spaces?’ That’s where these interiorized conditions came through, kind of creating layers of inside and outside.” Technical constraints further influenced the form. “We had to jump out of the digital world and decide how this was made in reality,” said Techentin. To minimize materials costs, the architects decided to work with schedule 40 steel tube, which is available in 24-foot lengths. Returning to Rhino, they broke apart their model and rescripted it accordingly. They modified their model again after learning what radiuses their metalworking contractor could accommodate. “It was kind of a balancing act between hitting these radiuses, the 24-foot lengths, and repetition—but how do you get difference and variety,” said Techentin.
  • Fabricator Ramirez Ironworks, Paramount Roll and Forming
  • Designers Warren Techentin Architecture
  • Location Los Angeles
  • Date of Completion April 2014
  • Material Schedule 40 steel tube
  • Process Rhino, scripting, bending, cutting, sleeving, welding, bolting, painting
Warren Techentin Architecture originally sought a digital fabricator for the project. But the quotes they received were too high, and they could not locate a manufacturer able to work with pipes longer than six feet. They contacted Paramount Roll and Forming, who rolled and bent the tubes by hand for one-tenth of what digital fabrication would have cost. “It wasn’t what we wanted, but in the end we wanted to see the project through,” said Techentin. Paramount sent the shaped steel to Ramirez Ironworks, where volunteers interested in metalworking helped assemble the structure. The design and fabrication team then disassembled it, painted the components, and transported them for reassembly on the site, a small courtyard in the Silver Lake neighborhood. La Cage Aux Folles invites active exploration. “My work draws great influence [from] architecture as something that you interface with, interact with—that envelops you, becomes part of an environment you participate with,” said Techentin, who overheard someone at the opening call his structure “a constructivist playground.” “We fully intended people walking around in there, lying down,” he said. “The surprise factor were the number of people who feel inspired to climb to the second and, more ambitiously, the third cages. We’re not encouraging it, but people do it.”
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UT Student Installation Takes SXSW

A room-filling parametric design makes its way from the classroom to Austin's famous music festival.

When Kory Bieg and his students at The University of Texas at Austin School of Architecture began working on Caret 6, they had no idea that it would wind up at this year’s South by Southwest (SXSW) music and arts festival. But the rippling, room-filling installation soon took on a life of its own. Within months, Bieg’s undergraduates—who had little previous exposure to digital design—had designed and fabricated Caret 6, and assembled and disassembled it twice, first at the TEX-FAB SKIN: Digital Assemblies Symposium in February, and then at Austin’s most famous annual gathering in March. Caret 6 developed out of a research studio taught by Bieg, who is also associate director of the regional digital fabrication and parametric design network TEX-FAB. Selected to chair TEX-FAB’s annual design competition, Bieg knew that he would soon face a problem: how to display the winning entry in a gallery much larger than it. He put his students to work on a solution. “The idea was to create a kind of counterpoint to the winning entry. [We] needed to fill space,” said Bieg. At the same time, the studio would teach the fundamentals of digital fabrication. “It was really just an experimental exploration of what these tools could produce,” he said. Caret 6’s white and grey diamond-shaped cells cascade from a central catenary vault with three column bases. Two secondary vaults project from either side. The front face of the structure flows down to the floor. “The idea is, we didn’t actually know who the winner [of TEX-FAB: SKIN] would be,” said Bieg. “We wanted to design a ground surface that was modular so that we could replace some of the cells with bases for their models.” The 17 students enrolled in Bieg’s course first created individual study models of aggregations and weavings amenable to digital fabrication. In an internal competition, they narrowed the field to three. Bieg broke the studio into teams, each of which experimented with creating volumetric versions of the designs. In a departure from typical parametric installations, Bieg and his students decided to stay away from patterns that gradually expand and contrast. “Our interest was not [in] doing subtlety, but local variations that are quite abrupt, like going from a large cell to a small cell,” said Bieg. “So part of that was a result of the way we structured it. Instead of aggregating cells, we designed a series of ribs.” The primary ribs form the vaults’ seams, while the secondary and tertiary ribs divide the structure into asymmetrical pockets. Halfway through the semester, Bieg called Alpolic Materials, whose Aluminum Composite Material (ACM)—a thin polyethylene core sandwiched between two sheets of aluminum—he had worked with on an earlier project. Alpolic agreed to donate supplies for Caret 6, “so we refined the design according to the material we had,” said Bieg. He also drafted students from UT engineering to calibrate the structure’s thickness, scale, and cantilever distances. “It kind of just evolved from these different processes coming in,” said Bieg.
  • Fabricator Kory Bieg and UTSOA Design Studio V
  • Designers Kory Bieg and UTSOA Design Studio V
  • Location Austin, Texas
  • Date of Completion February 2014
  • Material Alpolic Materials ACM, polypropylene, high-density polyethylene, binder clips, bolts, o-rings
  • Process Grasshopper, Kangaroo, 3ds Max, CNC milling, manual assembly
Back in the studio, Bieg’s students used 3ds Max for form studies and Kangaroo, a Grasshopper plug-in, to fit the tessellated diamond pattern to the vaults. They also used Grasshopper to develop an assembly system of binder rings, bolts, and o-rings. Bieg and his team fabricated the installation using UT’s CNC mill. They cut the vault pieces out of Alpolic ACM. The elements closest to the floor are polypropylene, while the intermediary pieces are high-density polyethylene. The students assembled and disassembled Caret 6 manually. At first, they tried working with a QR-code system, scanning each component to determine its location. When this took too long, they projected a digital model of the form on a screen, then called out each piece by number. For SXSW, where they had only six hours for assembly, they subdivided the structure into sections that could be quickly recombined on site. Caret 6 travels to Houston in September, where it will rejoin the entire TEX-FAB: SKIN show. But while the installation has already moved beyond its original context, Bieg insists that it remains rooted in the SKIN competition brief, which focused on building envelopes leveraging metal fabrication systems. “[Caret 6 is] not really a program per se, but more of an experiment about the same concepts that were part of the exhibits at TEX-FAB,” he said.
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An Impossible Stair by NEXT Architects

A folly in a Rotterdam suburb draws on residents' complex relationship with the city.

The residents of Carnisselande, a garden suburb in Barendrecht, the Netherlands, have a curious relationship with Rotterdam. Many of them work in the city, or are otherwise mentally and emotionally connected to it, yet they go home at night to a place that is physically and visually separate. When NEXT architects was tapped to build a folly on a hill in the new town, they seized on this apparent contradiction. “This suburb is completely hidden behind sound barriers, highways, totally disconnected from Rotterdam,” said NEXT director Marijn Schenk. “We discovered when you’re on top of the hill and jump, you can see Rotterdam. We said, ‘Can we make the jump into an art piece?’” NEXT designed The Elastic Perspective, a staircase based on the Möbius strip. “The idea of the impossible stair [is] you’re not able to continue your trip. At first it seems to be a continuous route, but once you’re up there, the path is flipping over,” explained Schenk. “That’s a reference to the feeling of the people living there.” To catch a glimpse of Rotterdam, users must turn their backs on Carnisselande. Yet while the view is in one sense the destination, the staircase ends where it started, in the reality of the garden suburb. NEXT began by experimenting with strips of paper and thin sheets of steel to form the staircase’s basic shape. The architects then turned to AutoCad, where they finalized the design before 3D printing a 1:200 scale model. NEXT worked with engineers at ABT throughout the process. They relied heavily on 3D design software, Schenk said, “because all the steel was sort of double-curved.”
  • Fabricator Mannen van Staal
  • Designers NEXT architects
  • Location Carnisselande, Barendrecht, Netherlands
  • Date of Completion June 2013
  • Material Cor-ten steel
  • Process modeling, AutoCad, CNC milling, bending, hand welding, cutting, robot welding
Mannen van Staal fabricated the staircase from seven steel panels custom-cut with a CNC machine, said project architect Joost Lemmens. They bent the plates, largely by hand, and assembled the entire structure in their factory, temporarily welding the pieces together. They then disassembled the structure for transport to the site, where the components were re-welded by hand and using a vacuum-cleaner-sized robot. Cor-ten was a practical choice on the one hand because the rust obscures the stitches used to reconnect the seven panels. In addition, said Schenk, “It’s weatherproof, and sustainable in the sense that we’re not using a toxic coating.” The choice of Cor-ten also holds aesthetic and cultural meaning. The orange of the staircase contrasts with the green of the hill. Plus, “it’s a material quite often used in artworks, so of course it refers to the work of Richard Serra [and others],” said Schenk. “I think in short what it’s about is the idea of making a jump, make people be able to make a jump to see the skyline of the city,” he concluded. “We’re using the Möbius strip to express the ambiguity of the people living there: feeling connected to Rotterdam but being somewhere else.”