Posts tagged with "epoxy":

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Clive Wilkinson Architects Makes a Superdesk

Endless table materializes intra-office connectivity in plywood, MDF, and epoxy.

When Culver City-based Clive Wilkinson Architects (CWA) sat down with representatives of the Barbarian Group to discuss renovating the advertising agency's new 20,000-square-foot office, one word kept coming up: connection. "Before, they were all in offices designed for one person, but crammed five in each, and scattered," recalled associate principal Chester Nielsen. "It was a pain. Bringing everyone into the open, and having them feel like they were all connected was super important." The architects elected to "surgically gut" the leased New York Garment District loft to create a central workspace for between 125-175 employees. To materialize the theme of connection, they zeroed in on the idea of a single work surface, an endless table later christened the Superdesk. With 4,400 square feet of epoxy-coated surface atop a support structure comprising 870 unique laser-cut plywood panels, the Superdesk is a triumph of programmatic creativity. "Building a big table was not an obvious solution," said Nielsen, "but it's a simple one." The Superdesk began as a series of sketches by president Clive Wilkinson. "Upon first impression we got to this squiggly table," said Nielsen. "It worked really well. Honestly, we've just been refining that." The table's undulating surface lifts and lowers, to indicate subtle divisions between departments, and to create arched overpasses above intra-office "cow paths." The grotto-like spaces under the archways double as intimate gathering areas for up to eight people.
  • Fabricator Machineous LLC
  • Designers Clive Wilkinson Architects
  • Location New York, NY
  • Date of Completion 2014
  • Material 2-by-4 lumber, plywood, plate steel, MDF, paint, epoxy
  • Process sketching, physical models, Revit, Rhino, laser cutting, bolting, bonding, painting, continuous epoxy pour
From the sketches, the architects built two physical models—the first rough, the second more refined—before taking the design into Revit and Rhino. There they further fine-tuned the form and prepared it for fabrication by Machineous LLC. "Machineous wanted the project very much; they were a good partner on this," said Nielsen. "We worked back and forth to tweak what we needed to make the table constructible." Machineous laser-cut the component parts, including the plywood ribs that shape the Superdesk's archways, using vintage automotive-industry robots. Machineous flat-packed the cut pieces and shipped them to New York, where the desk was assembled on site. The Superdesk's walls are framed in 2-by-4 lumber faced with plywood; plate steel brackets connect the various wood elements. Machineous bonded the MDF tabletop and painted it a shimmering white to give it the appearance of a single connected surface. The crowning achievement of the fabrication process—and the literal polish on the project—was a continuous epoxy pour, completed by rotating teams over a 24-hour period. Despite the complications inherent to prefabricating and installing a massive piece of furniture on opposite coasts, CWA and Machineous managed to deliver their innovative take on contemporary office culture both on time and within Barbarian Group's tight budget. "Something quite notable from the perspectives of both design and fabrication is that it's the same cost as going to Office Depot" for conventional desks, noted Nielsen. What is more, with plenty of surface area for laptops and the other, increasingly minimal, accoutrements of the modern workplace, and with a data and power track built into its walls, the Superdesk "is very, very flexible," he said. "Unlike a typical office [layout], it can change in a day."
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Goetz Brings Bucky Back

Fly's Eye Dome reproduction applies contemporary tools and materials to 1970s concept.

Thirty years after R. Buckminster Fuller's death, the visionary inventor and architect's Fly's Eye Dome has been reborn in Miami. Unveiled during Art Basel Miami Beach 2014, the replica dome, designed and fabricated by Goetz Composites in cooperation with the Buckminster Fuller Institute (BFI), pays tribute to Fuller both aesthetically and technologically. Constructed using contemporary materials and digital design tools, the new 24-foot Fly's Eye Dome (which serves as the pedestrian entrance to a parking garage in the Miami Design District) is yet further evidence that the creator of the geodesic dome was ahead of his time. BFI commissioned Goetz based on the firm's prior work restoring the original Fly's Eye Dome. At the end of that process, they created a 3D scan of the prototype for BFI's records. The digital files were the jumping-off point for the reproduction, for which ConForm Lab's Seth Wiseman provided critical design assistance, as did Daniel Reiser of DR Design. Wiseman produced a parametric model of the dome's truncations in Grasshopper, then compared his model to the 3D scan of the original to make sure the geometries matched. A 2012 reproduction of the Fly's Eye Dome, the MGM Butterfly Pavilion in Macau, China, constituted a practice round of sorts. "For Macau, we had a tight timeline: from the algorithm to shipment [we had] six weeks," said Wiseman. "We were able to review and tweak the geometry for the Miami dome—to refine it and make it more consistent with the original prototype."
  • Fabricator Goetz Composites
  • Designers R. Buckminster Fuller (prototype), Goetz Composites, Seth Wiseman, DR Design
  • Location Miami, Florida
  • Date of Completion 2014
  • Material fiberglass, epoxy, polycarbonate lenses, metal fasteners
  • Process 3D scanning, Grasshopper, CNC milling, infusing, gluing, fastening
Goetz, Reiser, and Wiseman introduced a few crucial changes into the Miami reproduction. "Bucky's original intent and concept was well-placed, but it suffered in execution," observed Wiseman. Fuller's prototype used a shingle system of overlapping truncations to shed water. As a result, the geometry was complicated. "The problem for us, from the manufacturing standpoint, is that it required four different molds," said Wiseman. "Though technology allows us to produce something of this complexity fairly easily, it's cost-prohibitive unless we're doing something on a production scale." The design team eliminated the shingle system, instead using a standard two-legged flange and coupler attachment to connect adjacent truncations on the dome's interior. The attachments are both mechanically fastened—for fidelity to Fuller's vision—and epoxy fitted—to meet engineering requirements. "If we were to do a third iteration, our hope is to develop joinery to eliminate the fasteners, for both assembly and aesthetic reasons," said Wiseman. In keeping with Fuller's commitment to all things cutting-edge, Goetz fabricated the reproduction using 21st-century materials and methods. They selected a PRO-SET epoxy originally developed for use on Coast Guard vessels to stand up to the South Florida weather, and replaced the glass domes with polycarbonate lenses sourced by Wasco and detailed with help from 3M. The composite forms were milled on a 5-axis CNC machine using EPS foam molds. (MouldCAM did some of the CNC cutting.) "The nice part with the Miami dome is that it's the next iteration," said Wiseman. "We've created a fire-retardant, code-compliant structure in the same vein [as the original]. I hate to say it, but I'm kind of excited to see a major storm hit Florida and see how it performs." For Goetz's Chase Hogoboom, the Fly's Eye Dome represents not just the history, but also the future of architecture. "Our background historically has been building state-of-the-art racing sailboats," he said. "We're seeing more and more demand for use of composites in architectural applications, mainly as a result of designers using programs that allow them to design very complicated shapes that need to be structural. And if you look at a Bucky dome, it's a complicated shape that needs to be structural."