Full-scale Prototype of a Lightweight and Robotic Incrementally Formed Copper Facade System with Standing Seam Connections

Paul Nicholas, Tim Schork, Dane Voorderhake

Publications: Chapter in Book/Report/Conference proceedingArticle in proceedingsResearchpeer-review

Abstract

Incrementally formed thin sheet metal enables lightweight structures that integrate ornament, structure
and skin - a trajectory of architectural and structural opportunity initialized by Prouve, Junkers, and
LeRicolais. However, where previously the need for a mold has limited rigidization to contexts of mass
production, mold-less Robotic Incremental Sheet Forming (RISF) provides new opportunities for
customized and bespoke panels. This paper reports on the computational design and fabrication of a
lightweight and highly differentiated copper façade system, using RISF. Central concerns are the
challenge of integrating customized structurally responsive geometry with design constraints typical of
a metal facade, and managing the material property changes induced by the fabrication process.
Where architectural models of material typically assume stability of physical properties, geometric
change implies property change in the RISF process. This paper describes a multi-scale approach to
predictive and generative modelling that incorporates these variables within the design process at
material and structural scales, allowing for material and fabrication informed design of a 1:1 prototype.
Original languageEnglish
Title of host publicationProceedings of the IASS Symposium 2018 : Creativity in Structural Design
Number of pages8
Publication date2018
DOIs
Publication statusPublished - 2018
EventIASS 2018: Creativity in Structural Design - MIT, Boston, United States
Duration: 16 Jul 201820 Jul 2018

Conference

ConferenceIASS 2018
LocationMIT
Country/TerritoryUnited States
CityBoston
Period16/07/201820/07/2018

Keywords

  • Digital design
  • incremental sheet metal forming
  • multiscale modeling
  • Industry collaboration

Artistic research

  • No

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