Make Architecture

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12. Final Fabrication: Interact_TILE

The goal of this final project is to design and build a modular system that utilizes the digital machines and techniques we’ve learned in class over the semester. I chose to fabricate an interactive wall system that incorporates LED lighting.

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INSPIRATION

For inspiration, I looked at interactive projects that involved modular system and lighting as well as some of my own past work for this class.

Brick_OPTIC

I chose to aggregate the Brick_Optic tile that I’ve made in week 7. Not only does the acrylic rod brings the light through, it also gives directionality to each tile.

https://makearchitecture.wordpress.com/people-2/juliet-hsu/7-form-work/

Brick_OPTIC by Juliet Hsu

LiTraCon

LiTraCon is a new type of translucent concrete made with fine concrete embedded with 4% optical glass. This light-transmitting concrete was developed in 2001 by Hungarian architect Aron  Losonczi working with scientists at the Technical University of Budapest.

Enteractive – Interactive Carpet

Designed by Electroland. Interactive environments which use layers of technology to intelligently register the movement of pedestrians through public space. Walkways, entries, and façade come alive in response to simple human actions.

Ada – Inteligent Room

A novel artificial organism, a creature in the shape of a space that can perceive and react to its surroundings. At the same time, her form facilitates a novel interaction between humans and machine that goes beyond the possibilities offered by a conventional computer, such as keyboard, mouse or joystick. Ada has sensory organs. She can see, hear and sense touch and contact. While Ada cannot communicate with words, she expresses herself through sounds, light and projections. Ada likewise learns how to synchronise her various components, such as the floor plates, the movable eyes and the light fingers. Ada is able to remember the visitors with whom she has played and whose gestures, movements and sounds she has observed. Swiss Expo 2002

White Noise / White Light by Meejin Yoon

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FABRICATION

Interact_TILE by Juliet Hsu

Tools and Components:

Prototype Form Work

  • Universal Laser Cutter (Bed size 18″ x 32″)
  • Laser Cut File
  • Acrylic Dowels, 1/2″ Ø
  • Acrylic sheet 18″ x 32″
  • Masking tape
  • Rockite 20 lbs
  • Mold release (Smooth-On Ease Release 200)
  • Paper cup or plastic bucket
  • Stirrer
  • Electric hand sander

Reusable Mold / Cast

  • 1 Sheet of plastic corrugation (or any sheet material)
  • Plastic sheeting to protect work surface
  • Silicon rubber (Smooth-On Mold Star 15), 4 trial pack

Water Jet Grid System

  • Omax Water Jet 2652 (Bedsize 26″ x 52″)
  • Template File
  • 2 sheets of 1/32″ Aluminum

Lighting & Misc

  • 15 Stick ‘n Click LED lights
  • (30) 1″ Compression Springs
  • 30″ x 18″ MDO

Directions:

DESIGN. The final project will be an aggregation of 15 tiles, each 6″ wide x 6″ height x 1/2″ depth. The total assembly will be 5 tiles across and 3 tiles down, the dimensions are 30″ wide x 18″ height x 1-1/2″ depth (including the support system and LED).

PROTOTYPE. The three basic tile patterns are designed to cover every corner of the nine square grid. By rotating the middle array and the corner array tiles, I can create a variety of aggregation that directs light in multiple ways.

Export Rhino file to .dxf using 2004 polyline setting for laser cut file. The prototype formwork are made with laser cut acrylic sheets which gives the tiles a smooth surface. However, they are also non-reusable formwork. Small notches are made in each prototype tile to allow for full integration of the backing system. Recommendation for 1/16″ acrylic sheet is 95 power and 8 speed for cutting on the Universal Laser Cutter.

Assembly formwork and tape all edges to prevent formwork from exploding or falling apart. Spray mold release on both interior of formwork and on the acrylic rods. Pour Rockite into mixing bucket, add water, and stir. Make a high slump mix to make sure the cement can get in between the rods. The demold  time is 10 min.

Laser cut formwork cut file 18″ x 24′.

Laser cut acrylic formwork and 1/2″ acrylic rods.

Acrylic formwork assembled.

Middle array prototype tile.

Corner array prototype tile w/ LED.

REUSABLE MOLD. To make four more tiles of each prototype, I need to make reusable molds. Make a container slightly larger than the prototype tiles. Tape all edges to make container water-tight. Mix part A and part B of Mold Star 15 thoroughly in 1:1 ratio. Pour mixed liquid into container. This product have 65 min pot life and 16 hours demold time according to the Smooth On specs. However, it is possible to remove the mold after 6-8 hours. Mold Star 15 have a high tear strength which is much needed when removing the prototype tiles and the acrylic rod array.

CASTING. Cut acrylic rod down to appropriate sizes and insert into rubber mold. Spray mold release on rubber mold and on the acrylic rods. Pour Rockite into mixing bucket, add water, and stir. Make a high slump mix to make sure the cement can get in between the rods. The demold  time is 10 min.

Rockite curing.

WATERJET. To waterjet the grid backing system, I need to make dash line cuts and cut out the support pieces. Join all vectors in cut file. Make a small tick mark in top left corner and use this as the starting point. Save two separate .dxf files (dash line & cut out pieces). Open .dxf in Omax Layout, set line quality to 3. Set lead in/out by using autopath. Set tool path, and click on auto generate. Save .ord file.

Waterjet cut file 1

Waterjet cut file 2

Before starting, check to see that the water pipe and gas pipe are turned on. When both levers are aligned with pipe, it is turned on. Next, lower the crank so that the nozzle touches aluminum sheet. Reverse the crank 1 full circle (1/2 circle kick back + 1/2 circle higher) to set appropriate nozzle height. Finally, raise the water level and click start.

Open the dash file in Omax Make. Set material to metal aluminum and thickness to 0.032″. Move nozzle head to top left corner and set zero in both x and y direction. Click on “Begin Machining”. When file is complete, open cut shape file and repeat without resetting the zero.

ASSEMBLY. Cut MDO to 30″ wide x 18″ high. Align the aluminum grid pieces at slotted edge and snap together the grid system. Fold tabs and screw down to MDO. Check tile orientation and stick LED light onto grid at acrylic rod location. Glue springs into place. Fold small tab into slot and hold tile in place. Finished!

2 Responses

  1. MARY says:

    I AM INTERESTED I CREATING AN AMBIANCE IN OUR RECEPTION HALLS WITH THE USE OF YOUR TECHNOLOGY.
    IN PARTICULAR i WOULD LIKE TO ACHIEVE AN INTERACTIVE dANCE FLOOR OR EVEN BETTER AND INTERACTIVE ROOM. I WANT MORE INFORMATION ON THE EFFECT ACHIEVED IN THE PHOTOS ABOVE, PARTICULARLY THE PHOT TITLED WHITE NOISE WHITE LIGHT.
    yOU CAN REACH ME AT 514 325-8665 MONTREAL CANADA

  2. Great advice as always, continue the good work!

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4.184 MAKE ARCHITECTURE

4.184 - ARCHITECTURAL DESIGN WORKSHOP:
[MAKING ARCHITECTURE] THE RESULTS
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Instructor: Nick Gelpi TA: Skylar Tibbits TA: Varvara Toulkeridou
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Class Times, Monday, 1-4pm - room 5-216
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4.184 is an intensive introduction to methods of making explored through a wide range of brief but focused 1-week exercises. We'll engage the real and leave behind representation in the focused context of this class gaining skills for utilizing a range of fabrication machines and technologies from lasercutting, waterjet, 3D printing, welding, formworking-molding, casting, gears, joints and composites.
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In this workshop we'll constrain ourselves to the territory of the 1:1. Students will represent architectural constructions at full scale and develop a more intimate relationship with technology by engaging the tools and techniques that empower us. We will gain access to the most cutting edge machines and technologies in the MARS lab at the Center for Bits and Atoms.
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The second layer of information for this course will be to look at a series of case studies in which construction methods and technologies have played a dominant role in the design process .
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Over the past 20 years, architects have focused on the technology of representation to create new ideas of what architecture could be. Looking back today, much of that research failed to substantially change the way we design buildings by focusing on apriori formal configurations. This class makes the contention that this failure comes from a lack of considerations of the potentials within fabrication knowledge. We look to the future of what building might become, given the expanded palette of personalize-able technologies available to us as architects. Students will participate in curious technological and material investigations, to discover the potentials, known and unknown, for these various technologies.
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The sub-disciplines of what's drawn and what's built have been compartmentalized and disassociated as the representational tools of architecture have distanced themselves from the techniques of making. At the same time the technologies for “making” in architecture have provided us with new possibilities for reinventing how we translate into reality, the immaterial representations of architecture.
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CONTENT, SCHEDULE, PEOPLE

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