Free-Form Architectural Façade Panels: An Overview of Available Mass-Production Methods for Free-Form External Envelopes

Alonso-Pastor, L.; Lauret-Aguirregabiria, B.; Vergara, Estéfana Castañeda; Domínguez-García, D.; Ovando-Vacarezza, G.

doi:10.1007/978-94-007-7790-3_20

Cited by 8 publications

(5 citation statements)

References 5 publications

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“…Forming methods utilize mechanical forces, heat, or steam to deform materials and create desired shapes, with examples including thermoforming, injection molding, CNC punching, welding, and more. Each method offers distinct advantages and can be applied based on the specific requirements and complexities of architectural projects (Alonso et al, 2014).…”

Section: Manufacturing Methodsmentioning

confidence: 99%

Coupling Non-planar Robotic Clay Deposition with Multipoint Forming to Optimize the Manufacturing of Double Curved Façade Panels

Salem,

Abdelmohsen,

Mansour

2023

eCAADe Proceedings

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Architects working on complex building geometries continually seek innovative processes to allow for feasible and cost-effective construction. The mass customization of double curved building façade panels has been specifically challenging regarding surface continuity, panel accuracy and waste reduction. With advanced digital design and fabrication tools, architectural firms such as ZHA, Gehry Technologies, and Atelier Jean Nouvel have been pushing the limits to achieve enhanced building envelope manufacturing solutions. Current research in materially-informed design-to-robotic production (D2RP) explores the impact of robotic fabrication on enhancing production practices. Several panel manufacturing methods have been proposed such as stretch bending, die forming, hydroforming, single and multipoint forming, the most successful being hybrid methods like multipoint stretch forming. In developing countries, the challenge of utilizing such materials and tools is amplified. In this paper, we introduce a method that couples the non-planar robotic deposition of clay as a material characterized by its longevity, reduced heat transfer, low cost, low maintenance lightweight and local abundance, with multipoint forming to optimize the manufacturing of double curved façade panels in hot arid climates. A 6-axis robotic arm was used to produce multiple functionally double-curved panels by depositing clay in a non-planar fashion and normal to the surface of a multipoint forming machine that was designed and manufactured using 3D printed movable actuators to create adaptive molds. A workflow was developed using Grasshopper for develop a streamlined coupling between the rapid code for the robotic simulation and depositing, and the multipoint forming synchronized actuator movement per clay panel, based on a given full building façade geometry. The resulting doublecurved facade panels were optimized structurally, materially, and spatially, and were shown to significantly reduce material waste with low environmental impact and accelerated rate of double-curved panel production.

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Section: Manufacturing Methodsmentioning

confidence: 99%

Coupling Non-planar Robotic Clay Deposition with Multipoint Forming to Optimize the Manufacturing of Double Curved Façade Panels

Salem,

Abdelmohsen,

Mansour

2023

eCAADe Proceedings

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“…In such cases, moulds are required to shape raw materials into their final forms. However, this necessitates a shift in focus towards the production, utilization, and waste generated by the mould implementation [33]. Free-form moulds are generally produced via digital manufacturing machinery implementing both subtractive and additive methods.…”

Section: State Of the Art-review Of The Main Processesmentioning

confidence: 99%

Parametric Assessment to Evaluate and Compare the Carbon Footprint of Diverse Manufacturing Processes for Building Complex Surfaces

Speroni,

Cavaglià,

Mainini

et al. 2023

Buildings

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At present, building design is faced with a need to properly manage complex geometries and surfaces. This fact is not only driven by the increased demand for visually stunning spaces but also stems from the rise of new design paradigms, such as “user-centred design”, that include bespoke optimization approaches. Nevertheless, the escalating adoption of customized components and one-off solutions raises valid concerns regarding the optimal use of energy and resources in this production paradigm. This study focuses on the Life Cycle Assessment of a novel Cement–Textile Composite (CTC) patented material. It combines a synthetic reinforcing textile with a customized concrete matrix, to generate rigid elements that are able to statically preserve complex spatial arrangements, particularly double-curvature surfaces. Moreover, the CTC offers a low-volume cost-effective alternative for custom-made cladding applications. The study performed a comparative carbon footprint assessment of the CTC production process in contrast to other technologies, such as CNC milling and 3D printing. To facilitate meaningful comparisons among diverse construction alternatives and to derive generalized data capable of characterizing their overall capacity, independent of specific production configurations, the present study implemented a generalized parametric shape of reference defined as a bounding box (BBOX), which encloses the volume of the target shape. Comparing different production technologies of the same shape with the same BBOX results in a significant carbon saving, up to 9/10th of the carbon footprint, when the CTC technology is adopted. The study therefore highlights the potential environmental advantages of CTC in the fields of architectural design and building engineering.

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“…El corte por hilo caliente es otro sistema de altas prestaciones, que a pesar de tener pocos ejemplos arquitectónicos, permite la ejecución de piezas de grandes dimensiones (26). Se pueden realizar elementos de doble curvatura, una vez que después del corte inicial con el hilo caliente, se gire la pieza de espuma, lo que hace de este sistema, una opción viable para la creación de moldes de forma libre.…”

Section: Tipo De Moldesunclassified

Nuevos métodos de fabricación digital de paneles de GRC de forma libre

et al. 2018

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Los paneles de forma libre de GRC son de gran aplicación en elementos de fachadas ligeras. Dichos paneles pueden fabricarse a través de una gran variedad de procesos. Sin embargo, a pesar de sus ventajas como la moldeabilidad, durabilidad y ligereza, se ven penalizados por el elevado precio de los correspondientes moldes, sobre todo si no hay una repetición suficiente de las piezas y la forma del panel difiere de lo convencional. Las nuevas tecnologías digitales permiten diversas posibilidades en el campo de la construcción y la producción de moldes con geometrías complejas. En el presente artículo se presenta una serie de métodos recientes en la fabricación de paneles de GRC de forma libre. Se discutirán ventajas e inconvenientes de dichos métodos, sobre todo la importancia del molde y su repercusión económica. Finalmente se extraerán conclusiones sobre la viabilidad técnica y las posibilidades que se abren con este análisis.

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Free-Form Architectural Façade Panels: An Overview of Available Mass-Production Methods for Free-Form External Envelopes

Cited by 8 publications

References 5 publications

Coupling Non-planar Robotic Clay Deposition with Multipoint Forming to Optimize the Manufacturing of Double Curved Façade Panels

Coupling Non-planar Robotic Clay Deposition with Multipoint Forming to Optimize the Manufacturing of Double Curved Façade Panels

Parametric Assessment to Evaluate and Compare the Carbon Footprint of Diverse Manufacturing Processes for Building Complex Surfaces

Nuevos métodos de fabricación digital de paneles de GRC de forma libre

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