“Every building shouldn’t be a one-off prototype.” That’s an underlying and provocative premise behind Katerra, a technology company that’s on a mission to optimize the way buildings are developed, designed, and constructed. Truth be told, the industry is primed for an overhaul. Construction companies traditionally invest less than 1 percent of revenue in new technologies—lower than every other major industry, according to the company’s literature. As a result, simultaneous productivity decreases and cost increases during the last several decades have created a quandary that requires fresh thinking and outside-of-the-box solutions. “The one thing that’s become very apparent is that—and this is typical in an up-cycle—it’s very difficult for architects and contractors to keep up with material costs, with cost escalation in these upturn markets,” explained Craig Curtis, FAIA, Architecture, Interior Design at Katerra. “And if you couple that with the fact that the skilled labor shortage is becoming more and more critical, where we’re headed right now as an industry I think is kind of a train wreck.” To help avert such a debacle, Katerra is completely rethinking the existing construction model and replacing it with technology, design, and supply chain innovations that aim to revolutionize the world of architecture and construction.
Posts tagged with "Mass Customization":
The New York architect and designer Dr. Haresh Lalvani has been researching the forms of living things-particularly those of shape codes akin to our own DNA makeup for 30 years. This research and analysis he then translates into sculptural forms that seem always to be merging and growing not fixed or frozen in place. At his solo exhibition, Mass Customization of Emergent Designs, at Moss Gallery at Design Miami in 2011, he used an algorithm to create 1,000 design variations of a common fruit platter out of a total of 100,000,000,000 possible designs before the computer crashed. Each platter was created with the same technology but preserved its inherent uniqueness. Lalvani’s claims this technology requires no economy of scale, as it costs no more for a factory to make all products different (mass-customization) than it costs to make them all the same (mass-production). His Brooklyn-made sculptures have appeared in galleries and public forums around the city including his beautiful 9-foot-tall, folded-titanium volume covers that were displayed at the entrance into the architecture room at MoMA for several years. Now you can see his morphological forms in the beautiful Columbia county countryside of Ghent, New York at the Omi International Arts Center. Lalvani has installed two sculptures X-POD and X-TOWER in the rolling landscape of the arts center. His X-TOWER for example is based on the towering form of California's Sequoia trees and emerges from a single flat metal sheet and raises into a towering almost pine cone shape form that is at once beautiful, mysterious and powerful as a work of art.
An ambitious designer used Rhino to design and fabricate 20 variations on a chair in four months.For a designer aiming to streamline the gap between design and manufacturing, parametric modeling tools are a natural solution. LA-based Alexander Purcell Rodrigues found a place to work in just such a way at the Neal Feay Company (NF), a 60-year old fabrication studio in Santa Barbara, California, that is known for its exceptional metalworking. Together, the designer and the fabrication studio created the Cartesian Collection of chairs, aptly named for the analytic geometry that helped facilitate close to 20 design variations on the same aluminum frame in just under four months. “Not only were we pushing the boundaries of aluminum fabrication, the aim was to simultaneously create a lean manufacturing process,” said Rodrigues. Using Rhino with a Grasshopper plugin, Rodrigues developed a design for a chair that weaves together the simplicity of Western design with the complex ornamentation of traditional Eastern aesthetics. While the lines of the chair are clean and smooth, intricate embellishments on the back traverse multiple planes and angles, all on a shrunken scale. The time savings involved in designing with Rhino allowed the creation of another 19 variations on the theme. Rather than working with large billets of aluminum, Rodrigues and NF’s Alex Rasmussen opted to fabricate the chair from ½-inch stock, with an option for wooden legs or an upholstered seat. “The most difficult thing was the back rest because it required the most unconventional process,” said Rasmussen. “Once it was bent into a the basic form, the back was put into a four-axis machine that works in an X, Y, Z, and rotational axis to apply texture.” An anodized finish, which transitions between two colors for an ombré effect, adds to the bespoke appearance. Working collaboratively to solve hiccups in the fabrication process was a key component to the success of the project, and experimenting with tool paths helped create new patterns. Manipulating the original design in Grasshopper accounted for even minute deflections in the real-world fabrication scenario. “With this formula, you can play with variables that go in a hundred directions and multiply quickly,” Rodrigues said of the freedom of working in the program. “The world is your oyster in Grasshopper.” The team worked with aluminum for the frame of the chairs, a material choice that was made in part due to the fact that NF specializes in the material. In addition, the lightweight metal allowed a greater degree of accuracy than injection or press molding. “You can get all the screw caps and holes so exact with a precision of perfection you can’t recreate in other materials,” said Rodrigues. “And experimenting with the ombré anodized finish, NF pushed the boundaries very well, for something so thin and elegant.”