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.
The arrangement of the four module types is defined by a designed height field, which was inserted into Grasshopper to strategize the gradient of the aperture pattern. These inform where the collective form is angled, introducing the folded curvature.
The individual module is a composition of three layers of fiberglass, with a metal washer inserted into six fiberglassed tabs. These composite tabs allow the insertion of a machine screw and nut, which secure a metal connection that subsequently connects to another module. These connections allow the modules to form a rigid grid, further stabilized by rubber washers at each connection.
The process began with the pursuit to develop a module with openings that varied in size from module to module, creating variation culminating in a gradient pattern. These apertures are dome/cone-shaped, allowing a multi-directional rigidity. The modules themselves are triangular, allowing the creation of a grid that allows infinite expansion and axes through which the collective form is angled.
The modules are divided into four different variations [SM, MED, LRG2, LRG1] created using the generative modeling tool, Grasshopper, to orchestrate the forms and dimensions of the apertures. The height of the modules is defined the maximum cut depth of the CNC mill, being limited to a maximum four inches.
Here is a flattened sequence demonstrating the parametric allocation of our four modules, their connection points, our system of detailing, and the streamlined and standardized angles of our bracketing. These will be assembled in an enveloping system attached to the ARCE structure in the courtyard outside.
Here is a look at different aperture shapes as well as patterns of gradation. We are trying to understand the efficiency of these shapes as they pertain to our material.
Utilizing the strength of fiberglass and its ability to embed materials during the lay-up process, we are looking at component fasteners that could be recessed into our production molds to facilitate a regularized/controlled system of connections. Further exploration with scripting attempts to systematize how these connections are included into the overall execution of a paneling system and form of installation.
small/shallow /cap >>> large/deep/aperture
ALL panels “open” at the same set height, with larger pieces having larger apertures and the smallest modules remaining capped. The system of panels will take on a gradient in size/aperture.
Control parameters deal with the fabrics ability to conform to a uniform surface and may be limited to the height restrictions of the tooling bed [4”].
The dome//cone module takes on multi-directional rigidity.
projects by iwamotoscott, matsys, and greg taylor. interest in structural apertures.