Construction Images Day 10 : 4:27:08

The threaded rod has been set into the concrete and the ground panels have been bolted in place.  The first rows are taking shape and beginning to transition from horizontal to vertical. 

Connection Update_3:25:08

Mock-up 4 Preperation

A nested sheet almost ready for fabrication, still without the proper fenestration.  (1) 4′ x 8′ aluminum sheet @ 1/16″ thickness.

-Nesting obviously becomes a major restriction, a possible direction for developing the connection efficiency!

Unrolled panels & folding connection…

Full Scale Mock-up v.2

A few images from the second full scale mock-up…

Conclusions:

-1/8″ Aluminum may be excessive in weight for panel + tab connection

-A perforated score @ 1/8″ aluminum is very difficult to bend.  Either the panel must be 1/16″ thickness or use a channel notch, which may only allow for 90 degree folds.

-Folded connection is very clumsy looking, may go for a triangular shape as well as cut away most of the back face of the connection b/c the first fold restrict almost all of the force

Tab Connection_2

A new tab connection which folds back on itself to restrict unfolding. A full scale mock-up has been sent for fabrication.

1/8 Scale Fabrication

An update with a few images of a full day of lasercutting the 1/8 scale model…

                 

                

                

1/8″ = 1′ – 0″ Scale Model Preparation_2:26:08

 

The code has been updated to:

-nest all text & panels

-Control the orientation of the connection, either inside or outside

The 1/8″ scale model will use a “tab” connection as the scale is too small to demonstrate the accurate connection.  The tab connection also utilizes the possibility of folding each panel with 1/8″ scale materials.  Two holes are provided in the tab connection to account for a standard staple to replace the full scale bolts.  The tab restricts almost all axis of rotation and should provide an estimate in the overall structural efficiency of the form.

1 of 4 nested sheets including:

-Tab connections

-Fenestration

-Unique 2 digit number

Connection Nest_2:25:08

 

The code has been updated to:

-add flat panels

-add connections on all interior panels, all edge panels still to be updated

-add three-digit annotation

-flatten and array for nesting on sheets

Still to be updated:

-edge connections

-flatten and array text

-add connection holes & tab

-possibly align perpendicular to panel

Three versions of the connection through code….

The most recent connection which eliminates the “U” shape and minimizes the arm lengths.  Still 2 up & 2 down with annotation.

A “Z” shaped connection which may be likely to unfold….

An early “T” shaped connection….

A first nesting attempt…

Connection Annotation_2:25:08

A few images of the connection annotation.  A three-digit number is applied to each connection describing:

-The number of the panel in the x direction

-The number of the panel in the y direction

-The edge of the panel : 0,1,2,3

This image shows a version with 2 connections up & 2 connections down for each panel.

A second iteration was produced which gradients the normal of the connection based on the surface curvature.  Not sure about its structural consequences but could be a nice detail….

Connection Tolerance per Iteration_ 2:25:08

Connection tolerance with a 10×35 panel layout.  Red dots indicating the panels connecting with a .001 tolerance. 

Connection tolerance with a 10×30 panel layout. 

The tolerance between panels does not directly influence any structural or connection factor as the connections account for each condition individually.  However, this did influence the processing of coding and resulted in an interesting discovery relating to the angle and intersection of panels with relation to the various degrees of surface approximation.

Connection Tests_2:12:08

A number of connection options to solve the following criteria:

-Resist two axis of rotation

-Resist panels from pulling away from each other

-Maintain structural integrity as it may carry most of the load

-Fabrication with either 3 axis CNC router or laser cutter, requiring flat sheet material