The four molds for the modules are laminated MDF, which were machined by the CNC mill. These molds were then seperated using a bandsaw and subsequently sanded smooth and finished using polyurethane.
To fiberglass the molds, each module receives multiple coats of mold release wax as well as two coats of liquid mold release after each cast. Each individual mold requires different shapes and sizes of fiberglass cloth, streamlined by using corresponding cardboard patterns while cutting the cloth.
These fabric patterns are resined and layered in sets of three for each mold, with a washer inserted in each tab. After curing, the panels are cleaned with a wax removal agent and the backs of the panels are sanded smooth. These are then connected using the connection exhibited in the schematic design and suspened using eyelet bolts. The eyelets are then used to suspend the collective form using cable.
These folding iterations are based off a cross-diagonal fold with inserted lateral and vertical folds that allow triangular modules to form. These create a structurally competent series of modules that can be strategized and fabricated in multiple ways.
Our documentation shows a “Plate” Iteration which is a field of modules on one plane which then can be folded and clipped to create a very stable and tessellated surface. In the “Strip” Iteration, the modules are arranged into a series of offset strips which are then clipped and connected together to create a flexible plane. The “Column/Compression” Iteration shows the strength of the module in compression, being secured as a column that can support a sizeable weight.
The last images show the 2D image of the folding pattern as well as the Grasshopper definition used to construct them. The definition allows skewing of the field of modules as well.